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(12) Patent Application Publication (10) Pub. No.: US 2009/0286914 A1 Crowe Et Al

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(12) Patent Application Publication (10) Pub. No.: US 2009/0286914 A1 Crowe Et Al US 20090286914A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2009/0286914 A1 Crowe et al. (43) Pub. Date: Nov. 19, 2009 (54) SEMI-CRYSTALLINE POLYMER Related U.S. Application Data COMPOSITION AND ARTICLE (60) Provisional application No. 60/636,531, filed on Dec. MANUFACTURED THEREFROM 17, 2004, provisional application No. 60/710,161, (75) Inventors: Christie W. Crowe, Alpharetta, GA filed on Aug. 23, 2005. (US); Glenn W. Cupta, Roswell, GA (US) Publication Classification (51) Int. Cl. Correspondence Address: CSK 3/28 (2006.01) OBLON, SPIVAK, MCCLELLAND MAIER & CSK 3/38 (2006.01) NEUSTADT, L.L.P. 194O DUKE STREET (52) U.S. Cl. ......................................... 524/404; 524/428 ALEXANDRIA, VA 22314 (US) (57) ABSTRACT (73) Assignee: SOLVAY ADVANCED Polymer composition comprising (i) at least one semi-crys POLYMERS, L.L.C., Alpharetta, talline polymer (SCP) chosen from polyamides, pol GA (US) yaryletherketones, liquid crystal polymers, polyalkylene Appl. No.: phthalates, polycarbonates, polyarylene Sulphides and pol (21) 11/721,980 yarylene oxides, and (ii) at least one oxide (OX) chosen from (22) PCT Fled: Dec. 15, 2005 acid oxides of an element having an electronegativity of at most 2.2 and amphoteric oxides, and (iii) at least one nitride (86) PCT NO.: PCT/EP2005/056803 (NJ) of an element having an electronegativity of from 1.3 to 2.5. Article comprising at least one part comprising the poly S371 (c)(1), mer composition as above described. Part of an article com (2), (4) Date: Jun. 16, 2007 prising the polymer composition as above described. Patent Application Publication Nov. 19, 2009 US 2009/0286914 A1 l Figure 2 US 2009/0286914 A1 Nov. 19, 2009 SEMI-CRYSTALLINE POLYMER achieved with the above detailed compositions and/or articles COMPOSITION AND ARTICLE is in general not sufficient, or requires a high amount of an MANUFACTURED THEREFROM expensive inorganic filler, Such as boron nitride; besides, using a very high amount of certain cheaper inorganic fillers, like aluminum oxide, can be detrimental to some other impor 0001. This application claims priority to U.S. provisional tant properties of the semi-crystalline polymer composition, application No. 60/636531, filed Dec. 17, 2004, and to U.S. like the electrical insulating properties. Then, improved com provisional application No. 60/7101.61, filed Aug. 23, 2005, positions and/or articles are still strongly needed. whose disclosures are incorporated herein by reference. 0007. A first objective of the present invention is to pro 0002 The present invention concerns a semi-crystalline vide a semi-crystalline polymer composition, in particular a polymer composition, in particular a polyphthalamide com polyphthalamide composition, which provides various position, and an article manufactured therefrom. advantages over prior art semi-crystalline polymer composi 0003 Most of prior art semi-crystalline polymer compo tions, in particular an improved thermal conductivity, without sitions and articles manufactured therefrom do not meet the retaining their drawbacks, in particular poor insulating prop requirements which are necessary for making them Suitable erties. for certain end-uses. In particular, they have usually a too low 0008. With this end in view, the present invention concerns thermal conductivity. To face this problem, it has already been a polymer composition comprising proposed to add various inorganic fillers to the semi-crystal 0009 at least one semi-crystalline polymer (SCP) chosen line composition. from polyamides, polyetherketones, liquid crystal polymers, 0004 For example, U.S. Pat. No. 6,600,633 describes an polyalkylene phthalates, polycarbonates, polyarylene Sul overmold for a disc drive actuator assembly to encapsulate phides and polyarylene oxides, and and Support an actuator coil material comprising (i) a base 0010 at least one oxide (OX) chosen from acid oxides of resin, Such as a liquid crystal polymer, a polyethylene naph an element having an electronegativity of at most 2.2 and thalate, a polyethylene terephthalate, a polybutylene tereph amphoteric oxides, and thalate, a polyamide, a polyphthalamide, a polyphenylene 0011 at least one nitride (NI) of an element having an Sulphide, a polycarbonate, a polyetheretherketone or a electronegativity of from 1.3 to 2.5. polyphenylene oxide, and (ii) a ceramic filler blended with 0012 For the purpose of the present invention, an “ele the resin Such as boron nitride, alumina, aluminum nitride, ment' is intended to denote an element from the Periodic magnesium oxide, zinc oxide, silicon carbide, beryllium Table of the Elements. oxide and chromium oxide (see col. 4.1. 10-25). While it is 0013 The value of the electronegativity of an element, as true that U.S. Pat. No. 6,600,633 further precises that the well as the acid, amphoteric or basic character of the oxide ceramic filler can notably consist of an indifferent mixture of derived from an elementata certain stage of oxidation that are the above listed fillers (see col. 4.1. 25-27), it does not dis to be taken into consideration for the purpose of the present close any specific combination of the above listed fillers; nor invention are those reported in the Periodic Table of the Ele does it suggest any benefit that would result from Such a ments edited by J. Breysem, c/o VEL s.a., “Produits, appar specific combination; conversely, U.S. Pat. No. 6,600,633 eillage et foumitures pour le laboratoire', printed in Belgium gives a clear preference for the use of either boron nitride or in February 1987. of alumina (i.e. aluminum oxide) as sole ceramic filler (see col. 4, 1. 20-22). 0014 For the purpose of the present invention, an “aam 0005. Another example is specifically directed to polyph photeric oxide’ is intended to denote either a predominantly thalamide compositions: JP 2004/059,638, in the name of acid amphoteric oxide oran amphoteric oxide in the strictest Kuraray, teaches that a polyphthalamide composition excel meaning of the term (i.e. without acid or basic predomi lent in heat conductivity, heat resistance, low water absorp nance). A predominantly basic amphoteric oxide is not an tion and moldability, can be obtained by blending a polyph amphoteric oxide to the purpose of the present invention. thalamide containing 60-100 mole % terephthalic acid units 0015 Non limitative examples of polyetherketones suit and 60-100 mole% 1.9-nonanediamine and/or 2-methyl-1.8- able to the purpose of the present invention are polyethere octanediamine units with a heat conductive filler and option therketoneketones (PEEKK), polyetherketoneketones ally a plasticizer. Examples of suitable heat conductive fillers (PEKK), polyetherketoneetherketones (PEKFK) and poly are listed in section.0020; among them are, notably, calcium etheretherketones (PEEK). Among polyetherketones, PEEK silicate whiskers, carbon fibers, metal oxides, metal powders, polymers are preferred. alumina, oxides Such as gold, silver, copper, iron, aluminum, 0016 Non limitative examples of liquid crystal polymers magnesium, beryllium and titanium oxides, boron nitride and Suitable to the purpose of the present invention are liquid aluminum nitride. While JP 2004/059,638 mentions that, crystal polyesters, notably the liquid crystal polyesters com generically speaking, the heat conductive filler can consist of mercialized by SOLVAY ADVANCED POLYMERS, L.L.C. one, two or more of the above listed fillers, the 6 therein as XYDAR(R) liquid crystal polyesters. exemplified compositions all comprise a sole ceramic filler 0017 Nonlimitative examples of polyalkylene phthalates (see table 1); more generally, like U.S. Pat. No. 6,600,633, JP suitable to the purpose of the present invention are polyeth 2004/059,638 does not describe any specific combination of ylene naphthalenes, polyethylene terephthalates and polybu the above listed fillers, nor does it suggest any benefit that tylene terephthalates. could result from Such a specific combination of inorganic 0018 Non limitative examples of polyarylene sulphides fillers. Suitable to the purpose of the present invention are polyphe 0006. The compositions and/or articles disclosed in U.S. nylene Sulphides, notably the polyphenylene Sulphides com Pat. No. 6,600,633 and JP 2004/059,638 still present several mercialized by SOLVAY ADVANCED POLYMERS, L.L.C. drawbacks. The improvement in thermal conductivity as PRIMEF(R) polyphenylene sulphides. US 2009/0286914 A1 Nov. 19, 2009 0019. The semi-crystalline polymer (SCP) has advanta ably, poly(tere?iso)phthalarnides further comprise recurring geously a heat deflection temperature of above 80°C. under a units formed by the polycondensation reaction between at load of 1.82 MPa when measured according to ASTM D648. least one aliphatic diacid and at least one aliphatic diamine. In 0020. The semi-crystalline polymer (SCP) is advanta addition, poly(tere?iso)phthalamides are preferably free of geously a polycondensation polymer. In addition, the semi recurring units formed by the polycondensation reaction crystalline polymer (SCP) comprises advantageously recur between o-phthalic acid and at least one diamine. ring units comprising at least one arylene group. The semi 0034) For the purpose of the present invention, polytereph crystalline polymer (SCP) is preferably a polycondensation thalamides are defined as aromatic polyamides of which more polymer comprising recurring units comprising at least one than 50 mole % of the recurring units are formed by the arylene group. polycondensation reaction between terephthalic acid and at 0021. The semi-crystalline polymer (SCP) is preferably a least one diamine. polyamide. 0035 A first class of preferred polyterephthalamides con 0022. The polyamide can be notably an aliphatic polya sists of polyterephthalanides the recurring units of which are mide Such as nylon 6, nylon 66 or nylon 12, a polyamide of formed by the polycondensation reaction between tereph which less than or equal to 50 mole % of the recurring units thalic acid and at least one aliphatic diamine class (I). comprise at least one aromatic group, or an aromatic polya 0036) A second class of preferred polyterephthalamides mide as defined hereafter.
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