EP4626953A1 - Hydrolytically stable polyarylene sulfide composition - Google Patents
Hydrolytically stable polyarylene sulfide compositionInfo
- Publication number
- EP4626953A1 EP4626953A1 EP23898591.5A EP23898591A EP4626953A1 EP 4626953 A1 EP4626953 A1 EP 4626953A1 EP 23898591 A EP23898591 A EP 23898591A EP 4626953 A1 EP4626953 A1 EP 4626953A1
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- European Patent Office
- Prior art keywords
- polymer composition
- polymer
- aged
- electric vehicle
- temperature
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L81/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
- C08L81/02—Polythioethers; Polythioether-ethers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G75/00—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen, or carbon in the main chain of the macromolecule
- C08G75/02—Polythioethers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G75/00—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen, or carbon in the main chain of the macromolecule
- C08G75/02—Polythioethers
- C08G75/0204—Polyarylenethioethers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G75/00—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen, or carbon in the main chain of the macromolecule
- C08G75/02—Polythioethers
- C08G75/0204—Polyarylenethioethers
- C08G75/0209—Polyarylenethioethers derived from monomers containing one aromatic ring
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G75/00—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen, or carbon in the main chain of the macromolecule
- C08G75/20—Polysulfones
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D181/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur, with or without nitrogen, oxygen, or carbon only; Coating compositions based on polysulfones; Coating compositions based on derivatives of such polymers
- C09D181/02—Polythioethers; Polythioether-ethers
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J181/00—Adhesives based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur, with or without nitrogen, oxygen, or carbon only; Adhesives based on polysulfones; Adhesives based on derivatives of such polymers
- C09J181/02—Polythioethers; Polythioether-ethers
Definitions
- Plastic materials are often employed in the electric vehicle for various electronic components, such as in high voltage connectors, power converter housings, battery assembly housings, inverters, busbars, twisted cables, individual sense lead wires, wire crimps, grommet moldings, quick connectors, tees, interconnects, guide rails, sealing rings (e.g., brushless direct current sealing rings, battery cell sealing rings, etc.), etc.
- plastic materials especially when reinforced with glass fibers, often used in such components exhibit poor mechanical characteristics (e.g., tensile strength and impact resistance) when exposed to moisture. This is particularly evident at elevated temperatures. As such, a need currently exists for a polymer composition that exhibits a higher degree of hydrolytic resistance at elevated temperatures.
- FIG.1 illustrates an electric vehicle including components that may incorporate a polymer composition as disclosed herein
- FIG.2 illustrates one embodiment of a busbar as may incorporate a polymer composition as disclosed herein
- FIG.3 illustrates a battery assembly that may employ components that may incorporate a polymer composition as disclosed herein
- FIG.4 illustrates an electronic system as may include components that may incorporate a polymer composition as disclosed herein
- FIG.5 illustrates a current sensor as may be included in an electronic system as in FIG.4
- FIG.6 illustrates an inverter system as may be present in an electric car including components that may incorporate a polymer composition as disclosed herein
- FIG.7 is a perspective view of one embodiment of a connector that
- the present invention is directed to a polymer composition that contains a polymer matrix including at least one polyarylene sulfide and inorganic fibers.
- the present inventors have discovered that the resulting composition can exhibit a unique combination of properties that enables it to be readily employed in a wide variety of product applications (e.g., electric vehicle) even at relatively small part thickness values, such as about 4 millimeters or less, in some embodiments about from about 0.2 to about 3.2 millimeters, in some embodiments from about 0.4 to about 2.5 millimeters, and in some embodiments, from about 0.8 to about 2 millimeters.
- the polymer composition may, for example, exhibit a tensile stress at break (i.e., strength) of from about 100 MPa to about 300 MPa, in some embodiments from about 120 MPa to about 250 MPa, in some embodiments from about 130 to about 220 MPa, and in some embodiments, from about 140 to about 200 MPa; a tensile break strain (i.e., elongation) of about 1% or more, in some embodiments from about 1.2% to about 8%, and in some embodiments, from about 1.5% to about 5%; and/or a tensile modulus of about 15,000 MPa or less, in some embodiments from about 1,000 MPa to about 12,000 MPa, in some embodiments from about 5,000 MPa to about 11,000 MPa.
- a tensile stress at break i.e., strength
- the tensile properties may be determined in accordance with ISO 527:2019 at a temperature of 23°C.
- the composition may also exhibit a flexural strength of about 20 MPa or more, in some embodiments from about 25 to about 200 MPa, in some embodiments from CICT-1181-PCT (2021P0117) about 30 to about 150 MPa, and in some embodiments, from about 35 to about 100 MPa and/or a flexural modulus of about 10,000 MPa or less, in some embodiments from about 500 MPa to about 8,000 MPa, in some embodiments from about 1,000 MPa to about 6,000 MPa, and in some embodiments, from about 1,500 MPa to about 5,000 MPa.
- the mechanical properties can also remain stable at such temperatures for a substantial period of time, such as for about 100 hours or more, in some embodiments from about 200 hours to about 3,000 hours, and in some embodiments, from about 250 hours to about 2,000 hours (e.g., 250, 500, 1,000, 1,500, or 2,000 hours).
- the tensile elongation after aging in the solution at 135°C for 1,000 hours may, for instance, be about 0.7% or more, in some embodiments from about 1% to about 8%, in some embodiments from about 1.2% to about 5%, and in some embodiments, from about 1.4% to about 4%, as determined at a temperature of about 23°C in accordance with ISO 527:2019.
- the ratio of the aged Charpy notched impact strength to the initial impact strength prior to such aging may also be about 0.6 or more, in some embodiments about 0.7 or more, and in some embodiments, from about 0.8 to 1.0.
- the Charpy notched impact strength after aging in the solution at 135°C for 1,000 hours may be about 1 kJ/m 2 or more, in some embodiments about 2 kJ/m 2 or more, in some embodiments from about 4 to about 20 kJ/m 2 , and in some embodiments, from about 5 to about 15 kJ/m 2 , as determined at a temperature of 23°C in accordance with ISO Test No.179-1:2010.
- the polymer composition may also exhibit good heat resistance and flame retardancy.
- the melting temperature of the composition may, for instance, be from about 250°C to about 440°C, in some embodiments from about 260°C to about 400°C, and in some embodiments, from about 280°C to about 380°C.
- the ratio of the deflection temperature under load (“DTUL”), a measure of short term heat resistance, to the melting temperature may still remain relatively high.
- the ratio may range from about 0.5 to about 1.00, in some embodiments from about 0.6 to about 0.95, and in some embodiments, from about 0.65 to about 0.85.
- the specific DTUL values may, for instance, range be about 260°C or more, in some embodiments from about 260°C to about 350°C, and in some embodiments, from about 265°C to about 320°C, such as determined in accordance with ISO 75:2013 at a load of 1.8 MPa.
- the polymer matrix typically constitutes from about 40 wt.% to about 90 wt.%, in some embodiments from about 45 wt.% to about 90 wt.%, and in some embodiments, from about 50 wt.% to about 70 wt.% of the polymer composition.
- the polymer matrix contains at least one polyarylene sulfide.
- polyarylene sulfides typically constitute from about 50 wt.% to 100 wt.%, in some embodiments from about 70 wt.% to 100 wt.%, and in some embodiments, from about 90 wt.% to 100 wt.% of the polymer matrix (e.g., 100 wt.%).
- the alkali metal sulfide can be, for example, lithium sulfide, sodium sulfide, potassium sulfide, rubidium sulfide, cesium sulfide or a mixture thereof.
- the alkali metal sulfide is a hydrate or an aqueous mixture
- the alkali metal sulfide can be processed according to a dehydrating operation in advance of the polymerization reaction.
- An alkali metal sulfide can also be generated in situ.
- the halogen atom can be fluorine, chlorine, bromine or iodine, and two halogen atoms in the same dihalo-aromatic compound may be the same or different from each other.
- o-dichlorobenzene, m-dichlorobenzene, p-dichlorobenzene or a mixture of two or more compounds thereof is used as the dihalo-aromatic compound.
- a monohalo compound not necessarily an aromatic compound
- the dihaloaromatic compound it is also possible to use a monohalo compound (not necessarily an aromatic compound) in combination with the dihaloaromatic compound in order to form end groups of the polyarylene sulfide or to regulate the polymerization reaction and/or the molecular weight of the polyarylene sulfide.
- the polyarylene sulfide(s) may be homopolymers or copolymers. For instance, selective combination of dihaloaromatic compounds can result in a polyarylene sulfide copolymer containing not less than two different units. For instance, when p-dichlorobenzene is used in combination with m- dichlorobenzene or 4,4'-dichlorodiphenylsulfone, a polyarylene sulfide copolymer can be formed containing segments having the structure of formula: S and segments having the or segments having the [0034] The linear, branched or crosslinked.
- Linear polyarylene sulfides typically contain 80 mol% or more of the repeating unit –(Ar–S)–. Such linear polymers may also include a small amount CICT-1181-PCT (2021P0117) of a branching unit or a cross-linking unit, but the amount of branching or cross- linking units is typically less than about 1 mol% of the total monomer units of the polyarylene sulfide.
- a linear polyarylene sulfide polymer may be a random copolymer or a block copolymer containing the above-mentioned repeating unit.
- Such monomers can be represented by the formula R'Xn, where each X is selected from chlorine, bromine, and iodine, n is an integer of 3 to 6, and R' is a polyvalent aromatic radical of valence n which can have up to about 4 methyl substituents, the total number of carbon atoms in R' being within the range of 6 to about 16.
- Examples of some polyhaloaromatic compounds having more than two halogens substituted per molecule that can be employed in forming a semi-linear polyarylene sulfide include 1,2,3-trichlorobenzene, 1,2,4-trichlorobenzene, 1,3- dichloro-5-bromobenzene, 1,2,4-triiodobenzene, 1,2,3,5-tetrabromobenzene, hexachlorobenzene, 1,3,5-trichloro-2,4,6-trimethylbenzene, 2,2',4,4'- tetrachlorobiphenyl, 2,2',5,5'-tetra-iodobiphenyl, 2,2',6,6'-tetrabromo-3,3',5,5'- tetramethylbiphenyl, 1,2,3,4-tetrachloronaphthalene, 1,2,4-tribromo-6- methylnaphthalene, etc., and mixtures
- the polyarylene sulfide can be functionalized.
- a disulfide compound containing reactive functional groups e.g., carboxyl, hydroxyl, amine, etc.
- Functionalization of the polyarylene sulfide can further provide sites for bonding between any optional impact modifiers and the polyarylene sulfide, which can improve distribution of the impact modifier throughout the polyarylene sulfide and prevent phase separation.
- the disulfide compound may undergo a chain scission reaction with the polyarylene sulfide during melt processing to lower its overall melt viscosity.
- disulfide compounds When employed, disulfide compounds typically constitute from about 0.01 wt.% to about 3 wt.%, in some embodiments from about 0.02 wt.% to about 1 wt.%, and in some embodiments, from about 0.05 to about 0.5 wt.% of CICT-1181-PCT (2021P0117) the polymer composition.
- the ratio of the amount of the polyarylene sulfide to the amount of the disulfide compound may likewise be from about 1000:1 to about 10:1, from about 500:1 to about 20:1, or from about 400:1 to about 30:1.
- Suitable disulfide compounds are typically those having the following formula: R 3 –S–S–R 4 [0036] wherein R 3 and R 4 may be the same or different and are hydrocarbon groups that independently include from 1 to about 20 carbons. For instance, R 3 and R 4 may be an alkyl, cycloalkyl, aryl, or heterocyclic group. In certain embodiments, R 3 and R 4 are generally nonreactive functionalities, such as phenyl, naphthyl, ethyl, methyl, propyl, etc. Examples of such compounds include diphenyl disulfide, naphthyl disulfide, dimethyl disulfide, diethyl disulfide, and dipropyl disulfide.
- R 3 and R 4 may also include reactive functionality at terminal end(s) of the disulfide compound.
- at least one of R 3 and R 4 may include a terminal carboxyl group, hydroxyl group, a substituted or non-substituted amino group, a nitro group, or the like.
- Examples of compounds may include, without limitation, 2,2'-diaminodiphenyl disulfide, 3,3'-diaminodiphenyl disulfide, 4,4'-diaminodiphenyl disulfide, dibenzyl disulfide, dithiosalicyclic acid (or 2,2’- dithiobenzoic acid), dithioglycolic acid, ⁇ , ⁇ '-dithiodilactic acid, ⁇ , ⁇ '-dithiodilactic acid, 3,3'-dithiodipyridine, 4,4'dithiomorpholine, 2,2'-dithiobis(benzothiazole), 2,2'- dithiobis(benzimidazole), 2,2'-dithiobis(benzoxazole), 2-(4'- morpholinodithio)benzothiazole, etc., as well as mixtures thereof.
- the melt flow rate of a polyarylene sulfide incorporated in a composition can be from about 100 to about 800 grams per 10 minutes (“g/10 min”), in some embodiments from about 200 to about 700 g/10 min, and in some embodiments, from about 300 to about 600 g/10 min, as determined in accordance with ISO 1133:2011 at a load of 5 kg and temperature of 316°C.
- g/10 min grams per 10 minutes
- Inorganic Fibers are also employed in the polymer composition to improve the thermal and mechanical properties of the composition.
- the inorganic fibers typically have a high degree of tensile strength relative to their mass.
- the ultimate tensile strength of the fibers is typically from about 1,000 to about 15,000 Megapascals (“MPa”), in some embodiments from about 2,000 MPa to about CICT-1181-PCT (2021P0117) 10,000 MPa, and in some embodiments, from about 3,000 MPa to about 6,000 MPa.
- MPa Megapascals
- the fibers may have a variety of different sizes, fibers having a certain size can help improve the mechanical properties of the resulting polymer composition.
- Glass fibers are particularly suitable, such as E-glass, E-CR glass, A-glass, C-glass, D-glass, AR-glass, R-glass, S1- glass, S2-glass, etc., as well as mixtures of any of the foregoing.
- Glass fibers that CICT-1181-PCT (2021P0117) are generally free of boron are particularly suitable.
- the glass fibers may include silica (SiO 2 ), alumina (Al 2 O 3 ), and oxides of calcium and magnesium (e.g., CaO, MgO, etc.), but are generally free of boron and optionally fluorides.
- the inorganic fibers may contain a sizing composition coated thereon to help improve hydrolytic resistance.
- the sizing composition may include an organosilane compound that is capable of forming Si-O-Si covalent bonds between the glass fiber surface and silanols obtained by hydrolysis of the silane compound, as well as between adjacent silanol groups. The resulting covalent bonds forms a crosslinked structure at the surface of the fibers that can enhance resistance to hydrolysis.
- Such organosilane compounds may, for instance, constitute from about 2 wt.% to about 40 wt.%, in some embodiments from about 2.5 wt.% to about 20 wt.%, and in some embodiments, from about 5 wt.% to about 15 wt.% of the solids content of the sizing composition (i.e., excluding water).
- the organosilane compound may, for example, be any alkoxysilane as is known in the art, such as vinlyalkoxysilanes, epoxyalkoxysilanes, aminoalkoxysilanes, mercaptoalkoxysilanes, and combinations thereof.
- the organosilane compound may have the following general formula: R 5 -Si-(R 6 ) 3 , wherein, R 5 is a sulfide group (e.g., -SH), an alkyl sulfide containing from 1 to 10 carbon atoms (e.g., mercaptopropyl, mercaptoethyl, mercaptobutyl, etc.), alkenyl sulfide containing from 2 to 10 carbon atoms, alkynyl sulfide containing from 2 to 10 carbon atoms, amino group (e.g., NH 2 ), aminoalkyl containing from 1 to 10 carbon atoms (e.g., aminomethyl, aminoethyl, aminopropyl, aminobutyl, etc.); aminoalkenyl containing from 2 to 10 carbon atoms, aminoalkynyl containing from 2 to 10 carbon atoms, and so forth; R 6 is an alkoxy group of
- Aminosilane compounds are particularly suitable and may include monomeric or oligomeric ( ⁇ 6 units) silanes.
- Aminotrialkoxysilanes may be employed in certain embodiments to form a three dimensional network of Si-O-Si covalent bonds at the surface and around the surface of the fibers.
- Aminodialkoxysilanes may likewise be employed in certain embodiments to form a hairlike structure on the surface of the fibers.
- the CICT-1181-PCT (2021P0117) dialkoxysilanes may nevertheless facilitate impregnation of the fiber bundles and wetting of the individual fibers by a polymer melt, as well as reduce the hydrophilicity of the surface of the fibers believed to contribute to resistance to hydrolysis.
- suitable aminosilanes may include, for instance, aminodialkoxysilanes, such as ⁇ - aminopropylmethyldiethoxysilane, N- ⁇ -(Aminoethyl)-gamma- aminopropylmethyldimethoxysilane, N- ⁇ -(Aminoethyl)- ⁇ -aminopropyl- methyldimethoxysilane, N- ⁇ -(Aminoethyl)- ⁇ -aminoisobutylmethyldimethoxy- silane, ⁇ -aminopropylmethyldimethoxysilane, N- ⁇ -(Aminoethyl)- ⁇ -aminopropyl- methyldiethoxysilane, etc.; aminotrialkoxysilanes, such as ⁇ - aminopropyltriethoxysilane, ⁇ -aminopropyltri-methoxysilane, N- ⁇ -(Aminoethyl)- ⁇ - aminopropyl
- the sizing composition may also contain one or more functionalized compounds that may be crosslinked to form a three-dimensional polymer network that can further enhance the hydrolytic resistance of the fibers.
- functionalized compounds may constitute from about 5 wt.% to about 90 wt.%, in some embodiments from about 10 wt.% to about 80 wt.%, and in some embodiments, from about 15 wt.% to about 70 wt.% of the solids content of the sizing composition (i.e., excluding water).
- the functionalized compound may be a blocked isocyanate.
- organic polyisocyanates include aliphatic isocyanates (e.g., trimethylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, butylidene diisocyanate, etc.); (cyclo)aliphatic isocyanates (e.g., isophorone diisocyanate (IPDI), 4,4'-diisocyanato-dicyclohexylmethane (HMDI), etc.); aromatic isocyanates (e.g., p-phenylene diisocyanate); aliphatic-aromatic isocyanates (e.g., 4,4′-diphenylene methane diisocyanate, 2,4- or 2,6-tolylene diisocyanate, etc.); as well as mixtures thereof.
- aliphatic isocyanates e.g., trimethylene diisocyanate, tetramethylene diisocyanate, hexamethylene diis
- the sizing composition may also contain a film-forming agent that can help protect the fibers from damage during processing and promote compatibility of the fibers with the polymer matrix.
- Particularly suitable film forming agents are polymers, such as polyurethanes, (meth)acrylate polymers, epoxy resin emulsions (e.g., based on epoxy bisphenol A or epoxy bisphenol F), epoxy ester resins, epoxy urethane resins, polyamides, etc., as well as mixtures of any of the foregoing.
- the film forming agent may include a polymer that is also functionalized, such as a polymer that includes a blocked isocyanate functionality as described above.
- Examples of such functionalized film-forming agents may include polyester-based and polyether-based polyurethanes that include a blocked isocyanate.
- such film forming agents may constitute from about 0.1 wt.% to about 50 wt.%, in some embodiments from about 1 wt.% to about 40 wt.%, and in some embodiments, from about 5 wt.% to about 30 wt.% of the solids content of the sizing composition (i.e., excluding water).
- Other additives may also be employed in the sizing composition, such as pH adjusters, lubricants, antistatic agents, antifoaming agents, crosslinking agents, etc.
- the sizing composition may be applied to the surface of the inorganic fibers in a variety of different ways. For example, the sizing composition may be applied as the fibers are formed out of a bushing.
- the entire composition may also be applied to the fibers in a single step, or one or more components of the sizing composition may be applied separately.
- a two-stage application process may be employed in which a polymer containing an anhydride and/or carboxylic acid functionality is applied in a first stage and a polymer containing an epoxy functionality is applied in a second stage. In this manner, the polymers may be crosslinked together only after application to the fiber surface.
- Other components of the sizing composition may be applied separately or in combination with one or both of the polymers.
- an organosilane compound may be employed in the polymer composition, such as in an amount of from about 0.1 to about 8 parts, in some embodiments from about 0.3 to about 5 parts, and in some embodiments, from about 0.5 to about 3 parts by weight per 100 parts by weight of the polyarylene sulfide(s).
- organosilane compounds can constitute from about 0.01 wt.% to about 3 wt.%, in some embodiments from about 0.02 wt.% to about 2 wt.%, and in some embodiments, from about 0.05 to about 1 wt.% of the polymer composition.
- the organosilane compound may be the same or different than the organosilane compound optionally employed in the sizing composition for the inorganic fibers.
- the organosilane compound may be an alkoxysilane, such as described above.
- alkoxysilane compounds that may be employed include mercaptopropyl trimethyoxysilane, mercaptopropyl triethoxysilane, aminopropyl triethoxysilane, aminoethyl triethoxysilane, aminopropyl trimethoxysilane, aminoethyl trimethoxysilane, ethylene trimethoxysilane, ethylene triethoxysilane, ethyne trimethoxysilane, ethyne triethoxysilane, aminoethylaminopropyltrimethoxysilane, 3-aminopropyl triethoxysilane, 3-aminopropyl trimethoxysilane, 3-aminopropyl methyl dimethoxysilane or 3-aminopropyl methyl diethoxysilane, N-(2-aminoethyl)- 3-aminopropyl trimethoxysilane, N-(2-
- an impact modifier may also be employed within the polymer composition.
- the impact modifier(s) may constitute from about 1 to about 20 parts, in some embodiments from about 2 to about 15 parts, and in some embodiments, from about 5 to about 10 parts by weight per 100 parts by weight of the polyarylene sulfide(s).
- the impact modifiers may constitute from about 0.1 wt.% to about 20 wt.%, in some embodiments from about 0.5 wt.% to about 15 wt.%, and in some embodiments, from about 1 wt.% to about 10 wt.% of the polymer composition.
- suitable impact modifiers may include, for instance, polyepoxides, polyurethanes, polybutadiene, acrylonitrile-butadiene-styrene, polyamides, block copolymers (e.g., polyether-polyamide block copolymers), etc., as well as mixtures thereof.
- an olefin copolymer is employed that is “epoxy-functionalized” in that it contains, on average, two or more epoxy functional groups per molecule.
- the copolymer generally contains an olefinic monomeric unit that is derived from one or more ⁇ -olefins. Examples of such monomers include, for instance, linear and/or branched ⁇ -olefins having from 2 to 20 carbon atoms and typically from 2 to 8 carbon atoms.
- Specific examples include ethylene, propylene, 1-butene; 3-methyl-1-butene; 3,3-dimethyl-1-butene; 1-pentene; 1-pentene with one or more methyl, ethyl or propyl substituents; 1- hexene with one or more methyl, ethyl or propyl substituents; 1-heptene with one or more methyl, ethyl or propyl substituents; 1-octene with one or more methyl, ethyl or propyl substituents; 1-nonene with one or more methyl, ethyl or propyl substituents; ethyl, methyl or dimethyl-substituted 1-decene; 1-dodecene; and styrene.
- Particularly desired ⁇ -olefin monomers are ethylene and propylene.
- the CICT-1181-PCT (2021P0117) copolymer may also contain an epoxy-functional monomeric unit.
- One example of such a unit is an epoxy-functional (meth)acrylic monomeric component.
- (meth)acrylic includes acrylic and methacrylic monomers, as well as salts or esters thereof, such as acrylate and methacrylate monomers.
- suitable epoxy-functional (meth)acrylic monomers may include, but are not limited to, those containing 1,2-epoxy groups, such as glycidyl acrylate and glycidyl methacrylate.
- Suitable epoxy-functional monomers include allyl glycidyl ether, glycidyl ethacrylate, and glycidyl itoconate. Other suitable monomers may also be employed to help achieve the desired molecular weight.
- the copolymer may also contain other monomeric units as is known in the art.
- another suitable monomer may include a (meth)acrylic monomer that is not epoxy-functional.
- Examples of such (meth)acrylic monomers may include methyl acrylate, ethyl acrylate, n-propyl acrylate, i-propyl acrylate, n-butyl acrylate, s-butyl acrylate, i-butyl acrylate, t-butyl acrylate, n-amyl acrylate, i-amyl acrylate, isobornyl acrylate, n-hexyl acrylate, 2- ethylbutyl acrylate, 2-ethylhexyl acrylate, n-octyl acrylate, n-decyl acrylate, methylcyclohexyl acrylate, cyclopentyl acrylate, cyclohexyl acrylate, methyl methacrylate, ethyl methacrylate, 2-hydroxyethyl methacrylate, n-propyl methacrylate, n-buty
- the copolymer may be a terpolymer formed from an epoxy-functional (meth)acrylic monomeric component, ⁇ -olefin monomeric component, and non-epoxy functional (meth)acrylic monomeric component.
- the copolymer may, for instance, be poly(ethylene-co-butylacrylate-co-glycidyl methacrylate), which has the following structure: CICT-1181-PCT (2021P0117) wherein, x, y, and z [0051]
- the relative portion of the monomeric component(s) may be selected to achieve a balance between epoxy-reactivity and melt flow rate.
- the epoxy-functional (meth)acrylic monomer(s) constitute from about 1 wt.% to about 20 wt.%, in some embodiments from about 2 wt.% to about 15 wt.%, and in some embodiments, from about 3 wt.% to about 10 wt.% of the copolymer.
- the ⁇ -olefin monomer(s) may likewise constitute from about 55 wt.% to about 95 wt.%, in some embodiments from about 60 wt.% to about 90 wt.%, and in some embodiments, from about 65 wt.% to about 85 wt.% of the copolymer.
- other monomeric components e.g., non-epoxy functional (meth)acrylic monomers
- the block copolymer may have an A-B or A-B-A block copolymer repeating structure, where A represents hard segments and B is a soft segment.
- impact modifiers having an A-B repeating structure include polyamide/polyether, polysulfone/polydimethylsiloxane, polyurethane/polyester, polyurethane/polyether, polyester/polyether, polycarbonate/polydimethylsiloxane, and polycarbonate/polyether.
- the polyether block may be derived from homo- or copolymers of cyclic ethers such as ethylene oxide, propylene oxide, and tetrahydrofuran.
- a siloxane polymer may also be employed in the polymer composition. Such siloxane polymer(s) typically constitute from about 0.05 to about 10 parts, in some embodiments from about 0.1 to about 8 parts, and in some embodiments, from about 0.5 to about 5 parts by weight per 100 parts by weight of the polyarylene sulfide(s).
- the siloxane polymer generally has a high molecular weight, such as a weight average molecular weight of about 100,000 grams per mole or more, in some embodiments about 200,000 grams per mole or more, and in some embodiments, from about 500,000 grams per mole to about 2,000,000 CICT-1181-PCT (2021P0117) grams per mole.
- the siloxane polymer may also have a relatively high kinematic viscosity at 25° C, such as about 10,000 centistokes or more, in some embodiments about 30,000 centistokes or more, and in some embodiments, from about 50,000 to about 50 x 10 6 centistokes, such as from about 1 ⁇ 10 6 to 50 ⁇ 10 6 centistokes.
- silicone denotes a monomer residue repeat unit having the structure: where R 1 and R 2 are a hydrocarbyl moiety, which is known as an “M” group in [0056]
- the silicone may include branch points such as which is known as a “Q” group or which is known as “T” group in [0057]
- hydrocarbyl denotes a univalent group formed by removing a hydrogen atom from a hydrocarbon (e.g., alkyl groups, such as ethyl, or aryl groups, such as phenyl).
- a siloxane monomer residue can be any dialkyl, diaryl, dialkaryl, or diaralkyl siloxane, having CICT-1181-PCT (2021P0117) the same or differing alkyl, aryl, alkaryl, or aralkyl moieties.
- each of R 1 and R 2 is independently a C 1 to C 20 , C 1 to C 12 , or C 1 to C 6 alkyl (e.g., methyl, ethyl, propyl, butyl, etc.), aryl (e.g., phenyl), alkaryl, ,aralkyl, cycloalkyl (e.g., cyclopentyl), arylenyl, alkenyl, cycloalkenyl (e.g., cyclohexenyl), alkoxy (e.g., methoxy), etc., as well as combinations thereof.
- R 1 and R 2 can have the same or a different number of carbon atoms.
- the hydrocarbyl group for each of R 1 and R 2 is an alkyl group that is saturated and optionally straight-chain. Additionally, the alkyl group in such embodiments can be the same for each of R 1 and R 2 of a polymer chain.
- alkyl groups suitable for use in R 1 and R 2 include methyl, ethyl, 1-propyl, 2-propyl, 1-butyl, isobutyl, t-butyl, or combinations of two or more thereof.
- the siloxane polymer can contain various terminating groups as an R 1 and/or R 2 group, such as vinyl groups, hydroxyl groups, hydrides, isocyanate groups, epoxy groups, acid groups, halogen atoms, alkoxy groups, acyloxy groups, ketoximate groups, amino groups, amido groups, acid amido groups, amino-oxy groups, mercapto groups, alkenyloxy groups, alkoxyalkoxy groups, or aminoxy groups as well as combinations thereof.
- a polymer composition can include a mixture of two or more siloxane polymers.
- a high molecular weight siloxane polymer can be proved by copolymerizing multiple siloxane polymers having a low weight average molecular weight (e.g., a molecular weight of less than 100,000 grams per mole) with polysiloxane linkers.
- the resin may be formed by copolymerizing one or more low molecular siloxane polymer(s) with a linear polydiorganosiloxane linker, such as described in U.S. Patent No.6,072,012 to Juen, et al.
- a substantially linear polydiorganosiloxane linker may have the following general formula: (R 3 (3-p) R 4 p SiO 1/2 )(R 3 2 SiO 2/2 ) x ((R 3 R 4 SiO 2/2 )(R 3 2 SiO 2/2 ) x ) y (R 3 (3-p) R 4 p SiO 1/2 ) wherein, each R 3 is a monovalent group independently selected from the group consisting of alkyl, aryl, and arylalkyl groups; each R 4 is a monovalent group independently selected from the group consisting of hydrogen, hydroxyl, alkoxy, oximo, alkyloximo, and aryloximo groups, CICT-1181-PCT (2021P0117) wherein at least two R 5 groups are typically present in each molecule and bonded to different silicon atoms; p is 0, 1, 2, or 3; x ranges from 0 to 200, and in some embodiments, from 0 to 100; and y ranges from
- the ethylene polymer may be a copolymer of ethylene and an ⁇ -olefin, such as a C 3 -C 20 ⁇ -olefin or C 3 -C 12 ⁇ -olefin.
- Suitable ⁇ -olefins may be linear or branched (e.g., one or more C1-C3 alkyl branches, or an aryl group).
- Particularly desired ⁇ -olefin comonomers are 1-butene, 1-hexene and 1- octene.
- the ethylene content of such copolymers may be from about 60 mole% to about 99 mole%, in some embodiments from about 80 mole% to about 98.5 mole%, and in some embodiments, from about 87 mole% to about 97.5 mole%.
- the ⁇ -olefin content may likewise range from about 1 mole% to about 40 mole%, in some embodiments from about 1.5 mole% to about 15 mole%, and in some embodiments, from about 2.5 mole% to about 13 mole%.
- the polymer composition may also contain a heat stabilizer.
- the heat stabilizer can be a phosphite stabilizer, such as an organic phosphite.
- suitable phosphite stabilizers include monophosphites and diphosphites, wherein the diphosphite has a molecular configuration that inhibits the absorption of moisture and/or has a relatively high Spiro isomer content.
- heat stabilizers typically constitute from about 0.1 wt.% to about 3 wt.%, and in some embodiments, from about 0.2 wt.% to about 2 wt.% of the composition.
- a nucleating agent may also be employed to further enhance the crystallization properties of the composition.
- boron-containing compounds e.g., boron nitride, sodium tetraborate, potassium tetraborate, calcium tetraborate, etc.
- alkaline earth metal carbonates e.g., calcium magnesium carbonate
- oxides e.g., titanium oxide, aluminum oxide, magnesium oxide, zinc oxide, antimony trioxide, etc.
- silicates e.g., talc, sodium-aluminum silicate, calcium silicate, magnesium silicate, etc.
- salts of alkaline earth metals e.g., calcium carbonate, calcium sulfate, etc.
- Boron nitride has been found to be particularly beneficial when employed in the polymer composition of the present invention.
- Boron nitride exists in a variety of different crystalline forms (e.g., h-BN - hexagonal, c-BN – cubic or spharlerite, and w-BN - CICT-1181-PCT (2021P0117) wurtzite), any of which can generally be employed in the present invention.
- the hexagonal crystalline form is particularly suitable due to its stability and softness.
- a crosslinking system may also be employed in combination with any optional impact modifier(s) to help further improve the strength and flexibility of the composition under a variety of different conditions.
- a crosslinked product may be formed from a crosslinkable polymer composition that contains the polyarylene sulfide(s), in conjunction with one or more of impact modifier(s), siloxane polymer(s), filler(s) and crosslinking system as well as any other additives.
- such a crosslinking system which may contain one or more crosslinking agents, typically constitutes from about 0.1 to about 15 parts, in some embodiments from about 0.2 to about 10 parts, and in some embodiments, from about 0.5 to about 5 parts per 100 parts of the polyarylene sulfide(s), as well as from about 0.05 wt.% to about 15 wt.%, in some embodiments from about 0.1 wt.% to about 10 wt.%, and in some embodiments, from about 0.2 wt.% to about 5 wt.% of the polymer composition.
- the compatibility and distribution of the polyarylene sulfide and impact modifier can be significantly improved.
- the impact modifier is capable of being dispersed within the polymer composition in the form of discrete domains of a nano-scale size.
- the domains may have an average cross-sectional dimension of from about 1 to about 1000 nanometers, in some embodiments from about 5 to about 800 nanometers, in some embodiments from about 10 to about 500 nanometers.
- the domains may have a variety of different shapes, such as elliptical, spherical, cylindrical, plate-like, tubular, etc. Such improved dispersion can result in either better mechanical properties or allow for equivalent mechanical properties to be achieved at lower amounts of impact modifier.
- Any of a variety of different crosslinking agents may generally be employed within the crosslinking system.
- the crosslinking system may include a metal carboxylate.
- the metal atom in the carboxylate can act as a Lewis acid that accepts electrons from the oxygen atom located in a functional group (e.g., epoxy functional group) of the impact modifier. Once it reacts with the carboxylate, the functional group can become activated and can be readily CICT-1181-PCT (2021P0117) attacked at either carbon atom in the three-membered ring via nucleophilic substitution, thereby resulting in crosslinking between the chains of the impact modifier.
- the metal carboxylate is typically a metal salt of a fatty acid.
- the metal cation employed in the salt may vary, but is typically a divalent metal, such as calcium, magnesium, lead, barium, strontium, zinc, iron, cadmium, nickel, copper, tin, etc., as well as mixtures thereof. Zinc is particularly suitable.
- the fatty acid may generally be any saturated or unsaturated acid having a carbon chain length of from about 8 to 22 carbon atoms, and in some embodiments, from about 10 to about 18 carbon atoms. If desired, the acid may be substituted.
- Suitable fatty acids may include, for instance, lauric acid, myristic acid, behenic acid, oleic acid, palmitic acid, stearic acid, ricinoleic acid, capric acid, neodecanoic acid, hydrogenated tallow fatty acid, hydroxy stearic acid, the fatty acids of hydrogenated castor oil, erucic acid, coconut oil fatty acid, etc., as well as mixtures thereof.
- Metal carboxylates typically constitute from about 0.05 wt.% to about 5 wt.%, in some embodiments from about 0.1 wt.% to about 2 wt.%, and in some embodiments, from about 0.2 wt.% to about 1 wt.% of the polymer composition.
- 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.
- a multi-functional crosslinking reagent may serve as a weak nucleophile, which can react with activated functional groups on the impact modifier (e.g., epoxy functional groups).
- activated functional groups on the impact modifier e.g., epoxy functional groups.
- the multi-functional nature of such molecules enables them to bridge two functional groups on the impact modifier, effectively serving as a curing agent.
- the multi-functional crosslinking agents generally include two or more reactively functional terminal moieties linked by a bond or a non-polymeric (non-repeating) linking component.
- the crosslinking agent can include a di-epoxide, poly-functional epoxide, diisocyanate, polyisocyanate, polyhydric alcohol, water-soluble carbodiimide, diamine, diol, diaminoalkane, multi-functional carboxylic acid, diacid halide, etc. Multi-functional carboxylic acids and amines are particularly suitable.
- multi-functional carboxylic acid crosslinking agents can include, without limitation, isophthalic acid, terephthalic acid, phthalic acid, 1,2-di(p- carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, 4,4'-bisbenzoic acid, 1,4- or 1,5-naphthalene dicarboxylic acids, decahydronaphthalene dicarboxylic acids, CICT-1181-PCT (2021P0117) norbornene dicarboxylic acids, bicyclooctane dicarboxylic acids, 1,4- cyclohexanedicarboxylic acid (both cis and trans), 1,4-hexylenedicarboxylic acid, adipic acid, azelaic acid, dicarboxyl dodecanoic acid, succinic acid, maleic acid, glutaric acid, suberic acid, azelaic acid and sebacic acid.
- dicarboxylic acid derivatives such as carboxylic acid diesters having from 1 to 4 carbon atoms in the alcohol radical, carboxylic acid anhydrides or carboxylic acid halides may also be utilized.
- aromatic dicarboxylic acids are particularly suitable, such as isophthalic acid or terephthalic acid.
- the multi-functional crosslinking agents may constitute from about 0.1 wt.% to about 10 wt.%, in some embodiments from about 0.2 wt.% to about 5 wt.%, and in some embodiments, from about 0.5 wt.% to about 3 wt.% of the polymer composition.
- the composition may be generally free of multi-functional crosslinking agents, or the crosslinking system may be generally free of metal carboxylates.
- compositions may include, for instance, nucleating agents, particulate fillers (e.g., talc, mica, etc.), pigments (e.g., black pigments), colorants, antioxidants, stabilizers, surfactants, lubricants, and other materials added to enhance properties and processability.
- nucleating agents such as a boron-containing particles.
- such particles When employed, such particles may constitute from about 0.01 wt.% to about 5 wt.%,in some embodiments from about 0.02 wt.% to about 2 wt.%, and in some embodiments, from about 0.05 wt.% to about 1 wt.% of the polymer composition.
- the boron- containing particles may exhibit a surprisingly high graphitization index such as greater than about 4, greater than about 5, or greater than about 6, in some embodiments from about 6 and about 10, and in some embodiments, from about 7 CICT-1181-PCT (2021P0117) and about 9.
- the graphitization index (also commonly termed graphite index) is a parameter that describes the structural quality of the boron-containing particles.
- Boron-containing particles such as boron nitride exist in several crystalline forms including hexagonal, which is similar to graphite in structure; cubic, which is analogous to diamond; and wurtzite, which is similar to lonsdaleite (also called hexagonal diamond).
- the boron-containing particles can have different degrees of crystallization.
- the graphitization index is derived from x-ray diffraction and is the ratio of the area under [(100) + (101)] peaks to the area under the (102) peak.
- the graphitization index describes the degree of order in the stacking of the layers along the c-axis of the material.
- the graphitization index can vary greatly, for instance from about 1 for well-ordered, highly crystalline particles up to about 50 for the so-called turbostratic particles, in which the layers show random rotations and translation about the normal.
- the boron-containing nucleating agent can also have a small particle size.
- the nucleating agent can have an average particle size of less than about 10 micrometers, in some embodiments from about 0.5 to about 10 micrometers, in some embodiments from about 1 micrometer to about 9 micrometers, and in some embodiments, from about 2 to about 8 micrometers, such as determined according to sedimentation techniques, laser diffraction methods, or any other suitable technique.
- particle size distribution can be determined according to a standard testing method such as ASTM D4464 or ASTM B822.
- the nucleating agent can also have a large specific surface area.
- the specific surface area can be, for example, greater than about 15 m2/g, greater than about 17 m 2 /g, or greater than about 19 m 2 /g. In one embodiment, the specific surface area can be quite large, for instance greater than about 30 m 2 /g.
- the specific surface area can be determined according to standard methods such as by the physical gas adsorption method (B.E.T. method) with nitrogen as the adsorption gas, as is generally known in the art and described by Brunauer, Emmet, and Teller (J. Amer. Chem.
- the combination of small particle size and large specific surface area can provide a boron-containing nucleating agent that has a CICT-1181-PCT (2021P0117) ratio of average particle size to specific surface area of between about 0.001 and about 1, for instance between about 0.01and about 0.8, or between about 0.02 and about 0.25.
- the nucleating agent particles can have any overall shape.
- the nucleating agent can include high aspect ratio particles having a needle-like or plate-like structure.
- the boron-containing nucleation agent can also be in the form of aggregated particles, in which the individual high aspect ratio particles are aggregated together with no particular orientation or in a highly ordered fashion, for instance via weak chemical bonds such as Van der Waals forces.
- Non-aggregated larger particles can also be utilized. For instance particles including a large number of stacked plate-like primary particles can be utilized as well as particles in which the primary structure is not evident, such as granulated or pulverized particles formed of larger sintered bodies.
- Suitable boron-containing nucleating agents may include any boron- containing material as is generally known in the art that may be provided with the disclosed characteristics.
- boron-containing nucleating agent materials can include, without limitation, boron nitride, sodium tetraborate, potassium tetraborate, calcium tetraborate, etc., as well as mixtures thereof.
- Boron nitride (BN) has been found to be particularly beneficial.
- Boron nitride exists in a variety of different crystalline forms (e.g., h-BN – hexagonal, c-BN – cubic or spharlerite, and w-BN – wurtzite), any of which can generally be employed in the present invention.
- the hexagonal crystalline form may be utilized in one embodiment due to its stability and softness. II.
- Such extruders may include feeding and venting ports and provide high intensity CICT-1181-PCT (2021P0117) distributive and dispersive mixing.
- the components may be fed to the same or different feeding ports of a twin-screw extruder and melt blended to form a substantially homogeneous melted mixture.
- Melt blending may occur under high shear/pressure and heat to ensure sufficient dispersion.
- melt processing may occur at a temperature of from about 100°C to about 500°C, and in some embodiments, from about 150°C to about 300°C.
- the apparent shear rate during melt processing may range from about 100 seconds -1 to about 10,000 seconds -1 , and in some embodiments, from about 500 seconds -1 to about 1,500 seconds -1 .
- Suitable techniques may include, for instance, injection molding, low-pressure injection molding, extrusion compression molding, gas injection molding, foam injection molding, low- pressure gas injection molding, low-pressure foam injection molding, gas extrusion compression molding, foam extrusion compression molding, extrusion molding, foam extrusion molding, compression molding, foam compression molding, gas compression molding, etc.
- an injection molding system may be employed that includes a mold within which the polymer composition may be injected. The time inside the injector may be controlled and optimized so that polymer matrix is not pre-solidified. When the cycle time is reached and the barrel is full for discharge, a piston may be used to inject the composition to the mold cavity. Compression molding systems may also be employed.
- the shaping of the polymer composition into the desired article also occurs within a mold.
- the composition may be placed into the compression mold using any known technique, such as by being picked up by an automated robot arm.
- the temperature of the mold may be maintained at or above the solidification temperature of the polymer composition for a desired time period to allow for solidification.
- the molded product may then be solidified by bringing it to a temperature below that of the melting temperature.
- the resulting product may be de-molded.
- the cycle time for each molding process may be adjusted to suit the polymer composition, to achieve sufficient bonding, and to enhance overall process productivity. IV.
- an electric vehicle such as a battery-powered electric vehicle, fuel cell-powered electric vehicle, plug-in hybrid- electric vehicle (PHEV), mild hybrid-electric vehicle (MHEV), full hybrid-electric vehicle (FHEV), etc.
- PHEV plug-in hybrid- electric vehicle
- MHEV mild hybrid-electric vehicle
- FHEV full hybrid-electric vehicle
- FIG.1 one embodiment of an electric vehicle 112 that includes a powertrain 110 is shown.
- the powertrain 110 contains one or more electric machines 114 connected to a transmission 116, which in turn is mechanically connected to a drive shaft 120 and drive wheels 122.
- the transmission 116 in this particular embodiment is also connected to an engine 118, though the description herein is equally applicable to a pure electric vehicle.
- the electric machines 114 may be capable of operating as a motor or a generator to provide propulsion and deceleration capability.
- the powertrain 110 also includes a propulsion source, such as a battery assembly 124, which stores and provides energy for use by the electric machines 114.
- the battery assembly 124 typically provides a high voltage current output (e.g., DC current at a voltage of from about 400 volts to about 800 volts) from one or more battery cell arrays that may include one or more battery cells.
- the powertrain 110 may also contain at least one power electronics module 126 that is connected to the battery assembly 124 (also commonly referred to as a battery pack) and that may contain a power converter (e.g., converter, etc., as well as combinations thereof).
- the battery assembly 124 can include a number of battery cells 158.
- the battery cells 158 may be stacked side-by-side to construct a grouping of battery cells, sometimes referred to as a battery array.
- the battery cells 158 are prismatic, lithium-ion cells.
- battery cells having other geometries (cylindrical, pouch, etc.) and/or chemistries (nickel-metal hydride, lead-acid, etc.) could alternatively be utilized within the scope of this disclosure.
- Each battery cell 158 includes a positive terminal (designated by the symbol (+)) and a negative terminal (designed by the symbol (-)).
- the battery cells 158 are arranged such that each battery cell 158 terminal is disposed adjacent to a terminal of an adjacent battery cell 158 having an opposite polarity.
- the terms “battery”, “cell”, and “battery cell” may be used interchangeably to refer to any type of individual battery element used in a battery system.
- the batteries described herein typically include lithium-based batteries, but may also include various chemistries and configurations including iron phosphate, metal oxide, lithium-ion polymer, nickel metal hydride, nickel cadmium, nickel-based batteries (hydrogen, zinc, cadmium, etc.), and any other battery type compatible with an electric vehicle.
- the busbar 10 includes a connector portion 14 at CICT-1181-PCT (2021P0117) either end that is configured to mate with respective terminations of two or more batteries.
- An insulative portion 16 e.g., coating or molded material that includes the polymer composition as described herein may cover a portion of the conductive material of the body 12.
- the insulative portion 16 can be applied to the surface of the conductive material 18. For instance, a bar or tube of the conductive material 18 can be inserted into a pre-formed tube of the insulating coating 16, e.g., an extruded tube sized and cut to the correct proportions, following which the busbar 10 can be shaped to any suitable form.
- the insulating coating can be applied to the surface of the conductive material 18 in the melt, and can solidify on the surface of the conductive material in the applied areas.
- a busbar may be provided in any suitable shape and size.
- a busbar may be used as a template for placing the individual battery cells so that they are uniform in each battery assembly manufactured.
- a busbar may hold individual batteries of a battery assembly 124 in place during the manufacturing process and thermal padding or injection-housings, which can be formed of a polymer composition as described herein, can be added without causing the individual battery cells to shift out of position.
- other components may also employ the polymer composition of the present invention.
- the EMI filter apparatus 325 includes an EMI filter card 340 and a pair of bolts 350, 352 which include a positive terminal (+) bolt 350 and a negative terminal ( ⁇ ) bolt 352 for coupling to a power source, e.g., the battery assembly 124.
- the EMI core 330 is coupled to the bolts 350, 352 by the bus bars 310.
- the EMI filter card 340 is also coupled between ground and the bus bars 310 via a pair of wires 334.
- An inverter module 320 includes a number of transistors (not shown). Transistors in an inverter module 320 switch on and off relatively rapidly (e.g., 5 to 20 kHz). This switching tends to generate electrical switching noise.
- An inverter system can include several components that can incorporate a polymer composition as disclosed including, without limitation, the EMI filter apparatus 325, e.g., as a housing and/or internal support structures, an EMI filter card 340, the bus bars 310, as well as connectors employed within the system.
- the EMI filter apparatus 325 e.g., as a housing and/or internal support structures
- an EMI filter card 340 e.g., as a housing and/or internal support structures
- the bus bars 310 e.g., as a housing and/or internal support structures
- an electrical connector that includes the polymer composition as described herein may be employed in an inverter system as in FIG. 7 or within another portion of an electric vehicle.
- An electrical connector can in general include a first connector portion that contains at least one electrical contact CICT-1181-PCT (2021P0117) and an insulating member that surrounds at least a portion of the connector portion.
- the insulating member may contain the polymer composition of the present invention.
- the first connector portion may be configured to mate with an opposing second connector portion that contains a receptacle for receiving the electrical contact.
- the second connector portion may contain at least one receptacle configured to receive the electrical contact of the first connector portion and an insulating member that surrounds at least a portion of the second connector portion.
- the insulating member of the second connector portion may also contain the polymer composition of the present invention.
- the periphery of the first insulator member 212 may extend beyond an end of the electrical pins 203 and the periphery of the second insulator member 218 may extend beyond an end of the receptacles 208.
- the base 203 and/or the first insulator member 212 of the first connector portion 202, as well as the base 201 and/or the second insulator member 218 of the second connector portion 204, may be formed from the polymer composition of the present invention.
- the first connector portion 202 may also include an identification mark 210 secured to or defined by the first protective member 212.
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Abstract
Description
Claims
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202263428140P | 2022-11-28 | 2022-11-28 | |
| PCT/US2023/080794 WO2024118406A1 (en) | 2022-11-28 | 2023-11-21 | Hydrolytically stable polyarylene sulfide composition |
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| Publication Number | Publication Date |
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| EP4626953A1 true EP4626953A1 (en) | 2025-10-08 |
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| EP23898591.5A Pending EP4626953A1 (en) | 2022-11-28 | 2023-11-21 | Hydrolytically stable polyarylene sulfide composition |
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| EP (1) | EP4626953A1 (en) |
| JP (1) | JP2025540590A (en) |
| KR (1) | KR20250116687A (en) |
| CN (1) | CN120380057A (en) |
| TW (1) | TW202440793A (en) |
| WO (1) | WO2024118406A1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20010029843A1 (en) * | 2000-01-31 | 2001-10-18 | Nichias Co., Ltd. | Chemical filter and manufacturing method thereof |
| CN101802062B (en) * | 2007-09-19 | 2012-07-04 | 汉高两合股份公司 | Highly damping expandable material and devices |
| US9494260B2 (en) * | 2012-04-13 | 2016-11-15 | Ticona Llc | Dynamically vulcanized polyarylene sulfide composition |
| KR102433360B1 (en) * | 2018-08-27 | 2022-08-16 | 주식회사 엘지에너지솔루션 | Electrode for lithium secondary battery and preparation method thereof |
| US12294185B2 (en) * | 2019-09-10 | 2025-05-06 | Ticona Llc | Electrical connector formed from a polymer composition having a low dielectric constant and dissipation factor |
| US20220243062A1 (en) * | 2021-02-04 | 2022-08-04 | Ticona Llc | Polymer Composition for an Electric Vehicle |
| JP2022159974A (en) * | 2021-04-05 | 2022-10-18 | 株式会社クラレ | resin composition |
-
2023
- 2023-11-21 CN CN202380082078.XA patent/CN120380057A/en active Pending
- 2023-11-21 JP JP2025525258A patent/JP2025540590A/en active Pending
- 2023-11-21 EP EP23898591.5A patent/EP4626953A1/en active Pending
- 2023-11-21 KR KR1020257021312A patent/KR20250116687A/en active Pending
- 2023-11-21 WO PCT/US2023/080794 patent/WO2024118406A1/en not_active Ceased
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| CN120380057A (en) | 2025-07-25 |
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| TW202440793A (en) | 2024-10-16 |
| JP2025540590A (en) | 2025-12-16 |
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