EP1060479A1 - Syndiotactic monovinylidene aromatic polymer film - Google Patents

Syndiotactic monovinylidene aromatic polymer film

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Publication number
EP1060479A1
EP1060479A1 EP19990905867 EP99905867A EP1060479A1 EP 1060479 A1 EP1060479 A1 EP 1060479A1 EP 19990905867 EP19990905867 EP 19990905867 EP 99905867 A EP99905867 A EP 99905867A EP 1060479 A1 EP1060479 A1 EP 1060479A1
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EP
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Application
Patent type
Prior art keywords
film
syndiotactic
percent
polymer
aromatic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP19990905867
Other languages
German (de)
French (fr)
Inventor
Robert P. Brentin
Gregg A. Motter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dow Chemical Co
Original Assignee
Dow Chemical Co
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Filing date
Publication date

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Classifications

    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/442Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from aromatic vinyl compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L25/00Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
    • C08L25/02Homopolymers or copolymers of hydrocarbons
    • C08L25/04Homopolymers or copolymers of styrene
    • C08L25/06Polystyrene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L25/00Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
    • C08L25/02Homopolymers or copolymers of hydrocarbons
    • C08L25/16Homopolymers or copolymers of alkyl-substituted styrenes
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04Homopolymers or copolymers of ethene
    • C08L23/08Copolymers of ethene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L53/00Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L53/02Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes

Abstract

This invention utilizes syndiotactic styrene polymer to produce a thin film suitable for insulating electrically conductive metal support structures from current conducting magnet wire. The addition of impact modifiers enables the thin sheet to withstand the mechanical stress of fabrication in motor assembly operations. The resultant sheet exhibits good heat resistance, electrical dielectric strength and moisture insensitivity which provides greater dimensional stability and resistance to hydrolysis.

Description

SYNDIOTACTIC MONOVINYLIDENE AROMATIC POLYMER FILM The present invention relates to impact modified syndiotactic monovinylidene aromatic polymers and film produced therefrom.

Electrical insulating film is used to provide insulation between an electrically conductive metallic support structure and current conducting magnet wire. Such films have typically been produced from polymers such as polyester, polyethylene terephthalate, polypropylene, atactic polystyrene and polyimide. Polyesters are known to absorb moisture, resulting in poor dimensional stability. Additionally, polyester has a relatively low glass transition temperature (-52 °C) which allows the film to soften under the load of tightly wound magnet wire. Polyester is also subject to hydrolysis which, over time in humid environments, will cause molecular weight degradation and insulation failure. Furthermore, polyester film requires the use of a secondary orientation step to achieve a sufficiently high level of crystallinity to increase heat resistance. Polyethylene terephthalate, polypropylene and atactic polystyrene polymers do not offer sufficient heat resistance in such insulation applications. Polyimide film provides excellent electrical insulation and heat resistance performance. However, these materials are very costly, making their use impractical in most applications. Other insulation substrates include kraft paper, rag paper, vulcanized fiber, and rag paper/PET. However, these materials can undergo considerable dimensional change due to moisture conditions.

US-A-5, 093,758 by Funaki et al. discloses an electrical insulating film which comprises a styrene polymer having a syndiotactic configuration (SPS) and containing not more than 1 ,000 ppm of residual aluminum derived from the catalyst used in the production of styrene polymer, and not more than 3,000 ppm residual styrene monomer. However, unmodified SPS film is inherently brittle which can cause film cracking during the slitting, cutting, and folding operations required in the fabrication of an electrical device. Additionally, this application requires SPS having very low levels of impurities which requires further polymer treatment.

Therefore, there remains a need for an electrical insulating film which does not crack during fabrication, has good ductility, electrical insulation and

-1 - heat resistance properties, good dimensional stability and a high glass transition temperature.

The present invention is an electrical insulating film comprising an impact modified syndiotactic monovinylidene aromatic polymer. The electrical insulating film can be used to provide electrical insulation between energized wires and a ground potential support structure.

The impact modified polymer used in the films of the present invention has high dielectric strength and is less affected by moisture than polyester, therefore, thinner film sheets can be used. Thinner insulation film sheets provide an increase in volume in the motor slot which can be used to add additional windings, increasing motor efficiency.

The present invention is an electrical insulating film comprised of a rubber modified syndiotactic monovinylidene aromatic polymer.

As used herein, the term "syndiotactic" refers to polymers having a stereoregular structure of greater than 90 percent syndiotactic, preferably greater than 95 percent syndiotactic, of a racemic triad as determined by 13C nuclear magnetic resonance spectroscopy.

Syndiotactic monovinylidene aromatic polymers are homopolymers and copolymers of vinyl aromatic monomers, that is, monomers whose chemical structure possess both an unsaturated moiety and an aromatic moiety. The preferred vinyl aromatic monomers have the formula

H2C=CR-Ar; wherein R is hydrogen or an alkyl group having from 1 to 4 carbon atoms, and

Ar is an aromatic radical of from 6 to 10 carbon atoms. Examples of such vinyl aromatic monomers are styrene, alpha-methylstyrene, ortho-methylstyrene, meta-methylstyrene, para-methylstyrene, vinyl toluene, para-t-butylstyrene, vinyl naphthalene, and divinylbenzene. Syndiotactic polystyrene is the currently preferred syndiotactic vinyl aromatic polymer. Typical polymerization processes for producing syndiotactic vinyl aromatic polymers are well known in the art and are described in US-A-4,680,353, US-A-5,066,741 ,

US-A-5,206,197 and US-A-5,294,685.

Typically, the weight average molecular weight (Mw) of the syndiotactic monovinylidene aromatic polymer is sufficient such that the polymer obtains

-2- good physical properties, yet low enough to have good melt processability, and is preferably between 150,000 and 400,000.

The impact modifier used in the films of the present invention can be any impact modifier which will impart sufficient strength and flexibility within the syndiotactic polymer such that it can be used in an insulating film. Typically this means that the film can be folded back onto itself without cracking. Examples of impact modifiers include but are not limited to styrene- ethylene-butylene-styrene block copolymer (SEBS), styrene-ethylene- propylene-styrene block copolymers (SEPS), polyolefins such as ethylene- octene and ethylene-hexene copolymers, polybutadiene, polyisoprene and copolymers of dienes with vinyl aromatic monomers such as butadiene- styrene and isoprene-styrene copolymers.

The impact modified syndiotactic monovinylidene aromatic polymer typically contains from 50, more preferably from 55, and most preferably from 60 to 95, preferably to 90 and most preferably to 85 percent by weight of the syndiotactic monovinylidene aromatic polymer, based on the total weight of the impact modified composition.

The impact modified syndiotactic monovinylidene aromatic polymer typically contains from 5, more preferably from 10 and most preferably from 15 to 50, preferably to 45 and most preferably to 40 weight percent of impact modifier, based on the total weight of the rubber modified composition.

In addition to the syndiotactic monovinylidene aromatic polymer and the impact modifier, other additives can also be used to produce the film of the present invention. Additives include as flame retardants, antioxidants, including hindered phenols such as IRGANOX™ 1010, IRGANOX™ 555, SEENOX™ 412S, and IRGANOX™ 1076, AND ULTRANOX™ 626, ULTRANOX™ 815, STAB PEP™ 36, Ethanox™ 398, Hostanox™ PAR 24 and Hostanox™ 03, 2,6-di-t-butyl-4-methylphenol, stearyl-β-(3,5-di-tert-butyl-4- hydroxyphenol)propionate, and triethylene glycol-bis-3-(3-tert-butyl-4-hydroxy- 5-methylphenyl)propionate or phosphorus-based compounds such as tris(2,4- tert-butylphenyl)phosphite and 4,4'-butylidenebis(3-methyl-6-tert-butylphenyl- di-tridecyl)-phosphite; antiblock agents such as fine particles composed of alumina, silica, aluminosilicate, calcium carbonate, calcium phosphate, and silicon resins; light stabilizers, such as a hindered amine-based compounds or benzotriazole-based compounds; lubricants such as stearic acid, behenic acid, zinc stearate, calcium stearate, magnesium stearate, ethylene bis- steramide, pentaerthritol tetrasterate, organo phosphate, mineral oil, trimellitate, polyethylene glycol, silicone oil, epoxidized soy bean oil, tricresyl phosphate, polyethylene glycol dimethyl ether, dioctyl adipate, di-n-butyl phthalate, butylene glycol montanate (Wax OP), pentaerethritol tetramontanate (TPET 141 ), aluminum mono-sterate, aluminum di-sterate, montanic acid wax, montanic acid ester wax, polar polyethylene waxes, and non-polar polyethylene waxes; extrusion aids, stabilizers such as bis(2,4-di- tertbutylphenyl)pentaerythritol and tris nonyl phenyl phosphite. Additionally, other polymers can be combined with the impact modified syndiotactic monovinylidene aromatic polymer. Nucleators may also be used in the present invention and are compounds capable of reducing the time required for onset of crystallization of the syndiotactic monovinylidene aromatic polymer upon cooling from the melt. Nucleators provide a greater degree of crystallinity in an extruded sheet and more consistent distribution of crystallinity under a variety of extrusion conditions. Higher levels of crystallinity are desired in order to achieve increased chemical resistance and improved heat performance. In addition, crystal morphology may be desirably altered. Examples of suitable nucleators for use herein are monoiayer of magnesium aluminum hydroxide, calcium carbonate, mica, wollastonite, titanium dioxide, silica, sodium sulfate, lithium chloride, sodium benzoate, aluminum benzoate, talc, and metal salts, especially aluminum salts or sodium salts of organic acids or phosphonic acids. Especially preferred compounds are aluminum and sodium salts of benzoic acid and CMO alkyl substituted benzoic acid derivatives. A most highly preferred nucleator is aluminum t s(p-tert-butyl)benzoate. The amount of nucleator used should be sufficient to cause nucleation and the onset of crystallization in the syndiotactic vinylaromatic polymer in a reduced time compared to compositions lacking in such nucleator. Preferred amounts are

-4- from 0.5 to 5 parts by weight based on the total weight of the impact modified composition.

Typically the impact modified syndiotactic monovinylidene aromatic polymer is prepared by blending the impact modifier with the syndiotactic monovinylidene polymer and other additives. Any means can be used to adequately reach uniform dispersion of the impact modifier and other additives in the syndiotactic monovinylidene aromatic polymer. This is generally accomplished by compounding the materials in an extruder and pelletizing. The compounded pellets are then melted and metered in an extruder to a sheet die to produce a sheet web which is cast onto a three roll stack to cool the web while maintaining uniform thickness and smooth surface quality. The extruded web is typically wound onto a roll for subsequent processing. The sheet is then slit to the proper width and cut to length. In preparing a motor assembly, small sections of plastic sheet are folded, cuffed and inserted into the slot liner of the motor to act as the electrical insulation.

The electrical insulating film can be produced on a conventional cast film/sheet extrusion line or on a cast tenter film/sheet line as disclosed in US-A-5, 093,758. The extruded sheet/film can be uni- or bi-axially stretched. When using conventional cast film/sheet line, such as a single screw extruder feeding a coat-hanger type die which casts the molten web onto a three roll cooling stack, a faster production rate can be achieved while obtaining crystallinity in the sheet of 10 - 50 percent. Levels of less than 10 percent are achieved in compositions containing high levels of impact modifier. High levels of crystallinity are preferred to ensure dimensional stability in end use applications which involves elevated temperatures and/or thermal cycling. Syndiotactic monovinylidene aromatic polymers such as SPS, can be sufficiently crystallized in one step on a cast extrusion line by extending the path and increasing the temperature the molten web experiences before being cooled on the roll stack. Typically, the extrusion line path will be from 5 - 50 cm, preferably from 20 to 40 cm with the melt temperature ranging from 310 to 330°C. Preferably the crystallinity is from 15, preferably from 20 and most preferably from 25 to 50, preferably to 45, and most preferably to 40 percent.

-5- The electrical insulating film is typically obtained in thicknesses of from 100 to 500 microns (μm), preferably from 150 to 400, more preferably from 150 to 300, and most preferably from 200 to 300μm.

The electrical insulating film of the present invention is characterized by a glass transition temperature of 100°C. This allows the film to maintain a higher modulus at elevated temperatures compared to alternative materials such as polyester. Additionally, the film has good dead fold characteristics which is highly desirable for electrical ground insulation applications. Polymers used to make this film are non-hydroscopic, therefore dimensional changes in the fabricated electrical insulation component are minimal. This allows for more predictable, tighter tolerance engineering of the electrical insulation system.

The electrical insulating film of the present invention has superior dielectric strength and breakdown voltage properties compared to commonly used polyester films and vulcanized papers. This will enable the electrical designer to down gauge the film thickness to allow more space in the device for copper windings leading to a more electrically efficient machine.

An additional advantage of the electrical insulating film of the present invention is its inherently bright white color obtained without the addition of pigments. Commonly used polyester films are tinted white with pigments such as titanium dioxide which incurs a loss in physical and electrical properties. The bright white color also provides a contrast background for the visual detection of flaws in the magnet wire coating.

The electrical insulating film of the present invention is useful for electrical insulation in slot liners, wedges and phase insulation for motors and generators. This includes hermetic motor/compressor sealed units, fractional horsepower motors, diaphragms and industrial laminations.

The following examples are provided to illustrate the present invention. The examples are not intended to limit the scope of the present invention and they should not be so interpreted. Amounts are in weight parts or weight percentages unless otherwise indicated. EXAMPLE 1

-6- The following materials are used in the following example as shown in Table

Syndiotactic Polystyrene (SPS) Mw 300,000 Impact Modifier styrene-ethylene-butylene-styrene block copolymer (SEBS) Kraton™ G1651 available from Shell Chemical

Nucleator Aluminum tris (p-tert-butyl)benzoate

-7- Table I

Sample SPS polvmer Impact Modifier Nucleator

T-1 85 percent 15 percent -

T-2 80 percent 20 percent -

T-3 79 percent 20 percent 1 percent

T-4 70 percent 30 percent -

T-5 60 percent 40 percent -

T-6 50 percent 50 percent -

T-7 84 percent 15 percent 1 percent

SPS, impact modifier and nucleator are compounded on a twin screw extruder and pelletized. The pellets are then melted and extruded into thin (approximately 250 μm thick) sheet under the conditions listed in Table II.

Table II

Zone 1 2 3 4 5

Extruder zone, 9C 330 322 310 310 310

Transfer line, 9C 310 310 310 310

Feed throat, 9C 38

Front roll 46 QC

Middle roll 62 eC Back roll 56 eC

Physical Property Characterization

Samples are injection molded and tested for physical properties. Results are tabulated in Table III.

Table III

Proper v T-1 T-2 T-3 T-4 T-5 T-6 LZ

DTUL@0.45 MPa, 2C 103 97 101 94 92 91 103

Vicat, aC 239 222 229 184 126 118 235

Elongation ©break, percent 17 47 34 101 73 79 23

Elongation@yield, percent 2.5 2.4 2.0 2.3 2.4 2.6 2.3

Tensile modulus, MPa 2500 2190 2270 1710 1280 1080 2470

Tensile strength ©break, 36 31 29 26 16 14 35 MPa

Tensile strength@yield, MPa 44 36 32 28 22 19 41

Flex modulus, MPa 2900 2550 2620 2000 1520 1310 2900

Flex strength, MPa 79 67 66 52 40 33 74

Specific gravity 1.020 1.015 1.014 0.998 0.984 0.973 1.021

Melt flow, g/10 min 5.5 4.5 4.0 3.2 2.3 1.9 4.6

Notch Izod impact, J/m 110 140 130 300 650 760 100

Thin Sheet Properties

Crystallinity in the thin sheet samples is determined using differential scanning calorimetry.

Sample T-1 L2 T-3 T-4 T-5 T-6 T-7

Heat Flow © 145-160°C, J/g 12.66 6.83 13.47 7.21 6.94 10.35 8.21

Heat Flow © 255-270°C, J/g 22.27 19.06 19.46 20.42 19.02 14.40 11.94

Crystallinity, percent 18.1 23.0 24.8 22.7 7.6 7.0 24.0

The need for a secondary operation to increase crystallinity is eliminated by selecting process conditions that keep the polymer melt above its glass transition temperature for a sufficient amount of time for crystallinity to develop before cooling. This includes having a melt temperature of 310°C and increasing the distance between the die lips and the first roll to approximately 25 cm.

-9- Once having produced the thin sheet, the film is slit and die stamped to the appropriate physical dimensions for insertion into a wire-wound electromechanical device.

-10-

Claims

CLAIMS:
1. An electrical insulating film produced from a composition comprising an impact modified syndiotactic monovinylidene aromatic polymer.
2. The film of Claim 1 wherein the polymer is syndiotactic polystyrene.
3. The film of Claim 1 wherein the impact modifier is selected from the group consisting of a styrene-ethylene-butylene-styrene copolymer, a styrene-ehtylene-propylene-styrene copolymer, an ethylene-octene copolymer and an ethylene-hexene copolymer.
4. The film of Claim 3 wherein the impact modifier is a styrene- ethylene-butylene-styrene copolymer.
5. The film of Claim 1 wherein the composition further comprises a nucleator.
6. The film of Claim 5 wherein the nucleator is aluminum tris (p-tert- butyl)benzoate.
7. The film of Claim 1 wherein the syndiotactic monovinylidene polymer is a copolymer of para-methyl styrene.
8. The film of Claim 1 wherein the film is from 100 to 500 ╬╝m thick.
9. The film of Claim 8 wherein the film is from 200 to 300 ╬╝m thick.
10. The film of Claim 1 wherein syndiotactic monovinylidene aromatic polymer has a crystallinity of from 7 to 50 percent.
11. The film of Claim 10 wherein the crystallinity is from 30 to 40 percent.
-11*
EP19990905867 1998-03-02 1999-02-09 Syndiotactic monovinylidene aromatic polymer film Withdrawn EP1060479A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US7656698 true 1998-03-02 1998-03-02
US76566P 1998-03-02
PCT/US1999/002710 WO1999045547A1 (en) 1998-03-02 1999-02-09 Syndiotactic monovinylidene aromatic polymer film

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EP1060479A1 true true EP1060479A1 (en) 2000-12-20

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Country Status (4)

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EP (1) EP1060479A1 (en)
JP (1) JP2002506269A (en)
KR (1) KR20010041494A (en)
WO (1) WO1999045547A1 (en)

Families Citing this family (1)

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Publication number Priority date Publication date Assignee Title
DE102010060176A1 (en) * 2010-10-26 2012-04-26 Ensinger Gmbh Insulating web

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JP2996472B2 (en) * 1989-10-09 1999-12-27 出光興産株式会社 Electrical insulating films and capacitor
JPH0693151A (en) * 1992-09-10 1994-04-05 Idemitsu Kosan Co Ltd Polyester resin composition
JPH06116454A (en) * 1992-10-07 1994-04-26 Idemitsu Kosan Co Ltd Thermoplastic resin composition
JP3139516B2 (en) * 1992-10-08 2001-03-05 出光興産株式会社 The thermoplastic resin composition
JP3292320B2 (en) * 1993-03-03 2002-06-17 出光興産株式会社 Impact resistant polystyrene composition
US5760105A (en) * 1993-06-04 1998-06-02 Idemitsu Kosan Co., Ltd. Styrenic resin composition
JPH08104785A (en) * 1994-10-05 1996-04-23 Idemitsu Kosan Co Ltd Impact-resistant polystyrene resin composition
CN1082059C (en) * 1994-11-29 2002-04-03 出光石油化学株式会社 Styrene polymer and molded articles
DE69703434D1 (en) * 1996-03-05 2000-12-07 Dow Chemical Co Form composition comprising syndiotactic vinyl aromatic polymer
EP1015517B1 (en) * 1997-09-12 2001-09-05 The Dow Chemical Company Toughened polymer blends
CA2305380A1 (en) * 1997-09-29 1999-04-22 National Research Council Of Canada Trivalent thrombin inhibitor

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Publication number Publication date Type
WO1999045547A1 (en) 1999-09-10 application
JP2002506269A (en) 2002-02-26 application
KR20010041494A (en) 2001-05-25 application

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