Crosslinkable polyarylene sulfide composition

Patent metadata

Field	Value
Publication number	US-10450461-B2
Application number	US-201615373945-A
Country	US
Kind code	B2
Filing date	Dec 9, 2016
Priority date	Dec 11, 2015
Publication date	Oct 22, 2019
Grant date	Oct 22, 2019

Abstract

A polymer composition that can exhibit excellent strength and flexibility under a variety of different conditions is provided. More particularly, the polymer composition contains a polyarylene sulfide, epoxy-functional polymeric impact modifier, and a crosslinking system that includes a metal carboxylate. In certain cases, the crosslinking system may also employ a crosslinking agent that is “multi-functional” to the extent that it contains at least two reactive, functional groups.

First claim

What is claimed is:

1. A crosslinkable polymer composition comprising:
a polyarylene sulfide;
from about 0.5 to about 50 parts of an impact modifier per 100 parts of the polyarylene sulfide, wherein the impact modifier includes an epoxy-functional polymer; and
from about 0.1 to about 15 parts of a crosslinking system per 100 parts of the polyarylene sulfide, wherein the crosslinking system includes a metal carboxylate.

2. The crosslinkable polymer composition of claim 1 , wherein polyarylene sulfides constitute from about 40 wt. % to about 95 wt. % of the composition.

3. The crosslinkable polymer composition of claim 1 , wherein the polyarylene sulfide is a polyphenylene sulfide.

4. The crosslinkable polymer composition of claim 1 , wherein the polyarylene sulfide is functionalized.

5. The crosslinkable polymer composition of claim 1 , wherein the epoxy-functional polymer contains an epoxy-functional (meth)acrylic monomeric component.

6. The crosslinkable polymer composition of claim 5 , wherein the epoxy-functional (meth)acrylic monomeric component is formed from glycidyl acrylate, glycidyl methacrylate, or a combination thereof.

7. The crosslinkable polymer composition of claim 5 , wherein the impact modifier further includes an α-olefin monomeric component.

8. The crosslinkable polymer composition of claim 1 , wherein the metal carboxylate is a metal salt of a fatty acid.

9. The crosslinkable polymer composition of claim 8 , wherein the salt contains a divalent metal cation.

10. The crosslinkable polymer composition of claim 8 , wherein the fatty acid has a carbon chain length of from 8 to 22 carbon atoms.

11. The crosslinkable polymer composition of claim 1 , wherein metal carboxylates constitute from about 0.05 wt. % to about 5 wt. % of the polymer composition.

12. The crosslinkable polymer composition of claim 1 , wherein the crosslinking system further comprises a multi-functional crosslinking agent.

13. The crosslinkable polymer composition of claim 12 , wherein the multi-functional crosslinking agent is a carboxylic acid.

14. The crosslinkable polymer composition of claim 12 , wherein multi-functional crosslinking agents constitute from about 0.1 wt. % to about 10 wt. % of the polymer composition.

15. The crosslinkable polymer composition of claim 1 , further comprising a heat stabilizer.

16. The crosslinkable polymer composition of claim 1 , wherein the impact modifier is dispersed within the polymer composition in the form of discrete domains having an average size of from about 5 to about 800 nanometers.

17. The crosslinkable polymer composition of claim 1 , further comprising an inorganic filler in an amount of from about 0.5 wt. % to about 50 wt. % of the composition.

18. A crosslinked product formed from the crosslinkable polymer composition of claim 1 .

19. The crosslinked polymer product of claim 18 , wherein the product exhibits a complex viscosity of 1,000 Pa-s or more, as determined by a parallel plate rheometer at an angular frequency of 0.1 radians per second, temperature of 310° C., and constant strain amplitude of 3%.

20. The crosslinked polymer product of claim 18 , wherein the product exhibits a notched Charpy impact strength of about 10 kJ/m 2 or more, as determined at a temperature of 23° C. in accordance with ISO Test No. 179-1:2010.

21. The crosslinked polymer product of claim 20 , wherein the product exhibits a notched Charpy impact strength of about 2 kJ/m 2 or more, as determined at a temperature of −30° C. in accordance with ISO Test No. 179-1:2010.

22. A method for forming a product, the method comprising melt blending a polymer composition that comprises a polyarylene sulfide, an impact modifier per hundred of the polyarylene sulfide, and a crosslinking system, wherein the crosslinking system includes a metal carboxylate and wherein the impact modifier includes an epoxy-functional polymer.

23. The method of claim 22 , wherein the melt blending occurs at a temperature of from about 100° C. to about 400° C.

24. The method of claim 22 , further comprising combining a multi-functional crosslinking agent with the polymer composition, and thereafter further melt blending the multi-functional crosslinking agent with the polymer composition.

25. A molded part comprising the polymer composition of claim 1 .

26. A melt-extruded sheet comprising the polymer composition of claim 1 .

27. A food tray comprising the polymer composition of claim 1 .

28. The food tray of claim 27 , wherein the tray contains a sidewall that extends upwardly from a lower wall to define a receptacle for one or more food products, wherein the sidewall, lower wall, or a combination thereof contain the polymer composition.

29. An overmolded structure comprising the polymer composition of claim 1 and a metal component.

Assignees

• Ticona Llc

Inventors

• Tu Xiaoyan
• Miller Kent
• Kindt Jared T
• Luo Rong
• Zhao Xinyu

Classifications

• B32B2307/4026

  within the layer by addition of a colorant, e.g. pigments, dyes · CPC title

• C08L81/02 Primary

  Polythioethers; Polythioether-ethers · CPC title

• B32B27/38

  comprising epoxy resins · CPC title

• B32B15/08

  of synthetic resin · CPC title

• B32B2307/3065

  Flame resistant or retardant, fire resistant or retardant · CPC title