EP4638601A1 - Pps composition, process for preparation, process for producing an article, and article made of the composition - Google Patents

Pps composition, process for preparation, process for producing an article, and article made of the composition

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Publication number
EP4638601A1
EP4638601A1 EP23832738.1A EP23832738A EP4638601A1 EP 4638601 A1 EP4638601 A1 EP 4638601A1 EP 23832738 A EP23832738 A EP 23832738A EP 4638601 A1 EP4638601 A1 EP 4638601A1
Authority
EP
European Patent Office
Prior art keywords
pps
composition
composition according
metal carbonate
thermoplastic elastomer
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.)
Pending
Application number
EP23832738.1A
Other languages
German (de)
French (fr)
Inventor
Tom Antonius Philomena ENGELS
Petrus Jacobus Wilhelmus Gerardus PALMEN
Wei Zhang
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.)
Envalior BV
Envalior BV
Original Assignee
Envalior BV
Envalior BV
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Envalior BV, Envalior BV filed Critical Envalior BV
Publication of EP4638601A1 publication Critical patent/EP4638601A1/en
Pending legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L81/00Compositions 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
    • C08L81/02Polythioethers; Polythioether-ethers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/0405Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
    • C08J5/043Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with glass fibres
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/54Silicon-containing compounds
    • C08K5/544Silicon-containing compounds containing nitrogen
    • C08K5/5445Silicon-containing compounds containing nitrogen containing at least one Si-N bond
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00Use of ingredients characterised by shape
    • C08K7/02Fibres or whiskers
    • C08K7/04Fibres or whiskers inorganic
    • C08K7/14Glass
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2381/00Characterised by the use 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; Polysulfones; Derivatives of such polymers
    • C08J2381/02Polythioethers; Polythioether-ethers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2400/00Characterised by the use of unspecified polymers
    • C08J2400/26Elastomers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2423/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2423/04Homopolymers or copolymers of ethene
    • C08J2423/08Copolymers of ethene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/18Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24Acids; Salts thereof
    • C08K3/26Carbonates; Bicarbonates
    • C08K2003/265Calcium, strontium or barium carbonate

Definitions

  • the present invention relates to a polyphenylene sulphide-based composition (hereinafter referred to briefly as PPS composition). More particular, the invention is directed to a PPS composition comprising polyphenylene sulphide (PPS), glass fibres and an impact modifier, which has high mechanical strength, good ductility and good impact resistance, as well as good flame retardancy.
  • PPS composition polyphenylene sulphide-based composition
  • the present invention also relates to a process for preparing the PPS composition, to a process for producing a molded article from the PPS composition, and to a molded article made of the PPS composition.
  • Poly(phenylene sulphide) also regularly written as polyphenylene sulphide, (and hereinafter also abbreviated as PPS)
  • PPS polyphenylene sulphide
  • PPS is known to exhibit high heat resistance and thermal stability, very good chemical resistance, good mechanical properties such as rigidity and tensile strength, and good dimensional stability, as well as good flame retardancy and good processing properties. Because of its advantageous properties, PPS is widely used as an alternative material for metal materials mainly in automobile parts, electrical and electronic parts, and housing equipment parts.
  • PPS compositions comprising PPS, elastomeric copolymers and fibre reinforcements are known in the art and are employed for multiple purposes.
  • the elastomeric copolymer typically is a thermoplastic copolymer, generally linear or branched, that exhibit an elastic deformation when a force is applied.
  • 34565-WO-PCT[2] - 2 - olefinic copolymers and functionalized derivates thereof are most frequently used.
  • fibre reinforcements glass fibres are mostly used.
  • compositions comprising polyphenylene sulphide (PPS), glass fibres and impact modifiers are described, for example, in EP0406553A2.
  • PPS polyphenylene sulphide
  • a problem of such compositions is the bad flame retardancy.
  • EP0406553A2 describes a PPS composition obtained by adding an olefin copolymer elastomer to a polyphenylene sulphide.
  • the polyphenylene sulphide is prior melt-kneaded with a non-blocked type polyfunctional isocyanate compound.
  • the composition is said to be excellent not only in impact resistance but also in aging resistance at high temperatures, and the composition can be advantageously used for moulding parts of automobile engines, parts for various machines, connectors for electric or electronic parts, bobbins and the like.
  • the composition may comprise other components. Specifically mentioned are the optional addition of a polyamide resin or a bromine-containing flame retardant, whereas many examples with glass fibre reinforcement are given. More particular, glass fibres are generally blended in an amount of 40 wt.%, relative to 48-54 wt.% of the isocyanate modified PPS and 6-12 wt.% of the olefine copolymer elastomer. Two examples with a bromine-containing flame retardant are described, one with 4 wt.% flame retardant having a UL94 flame retardancy rating of V-1, the other, with double the amount of flame retardant, having a rating of V-0.
  • the object of the present invention is to provide a PPS composition comprising PPS, an impact modifier and fibre reinforcement, which has good mechanical properties and impact strength, and which also has good flame retardancy properties without the use of a halogen containing flame retardant.
  • the PPS composition according to the invention comprising, next to PPS, elastomeric copolymer and glass fibre reinforcement, a metal carbonate, each in an amount as specified below: a.
  • compositions according to the invention combine good mechanical properties, such as sufficient tensile strength, elongation at break and impact resistance, together with a flame retardancy rating of V0 at 0.8 mm as measured according to UL94.
  • a flame retardancy rating of V0 at 0.8 mm as measured according to UL94.
  • EP3650501A1 describes polyarylene sulphide resin compositions comprising a polyarylene sulphide resin and an inorganic filler treated with a specific sizing agent. The amount of filler is up to 100 parts by mass (pbm) relative to 100 pbm of the polyarylene sulphide resin. Examples of the inorganic filler include calcium carbonate and magnesium carbonate.
  • Fibre reinforcement such as glass fibres
  • other components such as polyolefin-based elastomers
  • the composition comprises 35.5 wt.% of PPS, 30 wt.% GF, and 34 wt.% of CaCO3.
  • the composition does not comprise any impact modifier.
  • EP3650501A1 is silent about the about the problem solved by the present invention and about the effects according to the present invention.
  • US6849697B2 describes PPS compositions essentially containing PPS, olefinic elastomers containing epoxy groups, and a crosslinking agent containing functional groups which are reactive towards the epoxy groups. These compositions are claimed to have improved impact strength.
  • compositions may also contain other ingredients in quantities not detrimental to the properties of these compositions.
  • fillers and reinforcing materials are mentioned, such as, for example, glass fibres, which the composition may contain, in general, from 5 to 300% of the weight of PPS, and flame-retardant agents such as, for example, antimony salts, aryl chlorophosphates and chlorinated paraffins.
  • flame-retardant agents such as, for example, antimony salts, aryl chlorophosphates and chlorinated paraffins.
  • JP6809083B2 describes PPS compositions for heat dissipating members.
  • compositions comprise PPS, whiskers having a number average fibre diameter in the range of 2 to 50 micrometre ( ), and spherical fillers having a number 34565-WO-PCT[2] - 5 - a spherical filler, magnesium carbonate, calcium carbonate, glass beads, silica and the like can be used.
  • a thermoplastic elastomer can be blended as an optional component, if necessary.
  • the blending ratio is not particularly limited as long as the claimed effects of JP6809083B2 are not impaired. Most examples are with MgCO3 with amounts between 9 and 27 wt.%.
  • CN108026369A describes polyarylene sulphide resin compositions, comprising a polyarylene sulphide resin, (100 parts by weight), fillers (65 300 pbw) and carbon black (more than 0.2 pbw, arithmetic mean diameter is 10 ⁇ 15 nm), that are claimed to have improved bending fracture strain and suppressed sensitivity for oil and fat.
  • the composition may comprise granular fillers, among which mineral fillers, metal carbonates and metal sulphates, and fibrous fillers, among which glass fibres. to further improve toughness, the composition may comprise elastomers.
  • filler preferably CN108026369A uses glass fibre, calcium carbonate or combinations thereof. In the many examples these fillers are typically used in relatively large amounts: relative to 100 pbw polyarylene sulphide; 35-147 pbw (20 40 wt.%) of glass fibres; 35-92 pbw (20 30 wt.%) of CaCO3; 0.46-5.2 pbw (1.5 - 2 wt.%) of CB; 3.5 22 pbw (2-6 wt.%) of an elastomer.
  • JP6511785B2 describes a reinforced impact-modified PPS composition, and a resin moulded article thereof, that are claimed to have improved heat cycle resistance and self-tapping reliability.
  • the composition of JP6511785B2 comprises PPS, a polyolefin or a combination of polyolefins and a combination of reinforcement fibres and filler.
  • the combination of polyolefins comprises a functional group-containing olefin copolymer and a functional group- -olefin copolymer.
  • the combination of reinforcement fibres and filler comprises glass fibres and calcium carbonate in a ratio of 2:1 to 7:1.
  • the compositions in the examples of JP6511785B2 typically have a relative high content in CaCO3. Others are very low in content of the impact modifier.
  • the patent focuses on increasing the friction to be overcome by the torque to be applied during tightening of a self-tapping screw.
  • JP6511785B2 is silent about the problems underlying the present invention as well as about the measures for the solution according to the present invention.
  • 34565-WO-PCT[2] - 6 - by polyphenylene sulphide resin has high heat resistance, mechanical properties, chemical resistance, dimensional stability, and flame retardancy.
  • halogen content in a composition containing PAS resin is 900 ppm or JP6207809B2 describes a polyarylene sulphide resin composition having a reduced chlorine atom content, and a moulded article thereof, and a method for producing the polyarylene sulphide resin composition.
  • the composition of -fibrous filler, and (C) a fibrous filler is 900 ppm or JP6207809B2
  • the composition of JP6207809B2 preferably further comprises an amorphous resin, such as polycarbonate resins and polyphenylene ether resins.
  • the composition may further comprise other resins as long as the claimed effects are not impaired.
  • polyolefin elastomers are mentioned, next to several other resins.
  • Examples of the composition mentioned in JP6207809B2 comprise 35 wt.% of a polyarylene sulphide resin, 30 or 35 wt.% of CaCO3, 25 or 30 wt.% of glass fibres, and some examples further comprise 5 wt.% of an amorphous polyphenylene ether.
  • JP6207809B2 mentions the flame retardancy properties of polyarylene sulphide, it is silent about the problems underlying the present invention let alone about the measures for the solution to that problem as according to the present invention.
  • the PPS composition according to the present invention comprises the following components: a. Polyphenylene sulphide (PPS) in an amount in a range of 36 71.5 weight percentage (wt.%); b.
  • Glass fibres in an amount in a range of 25 45 wt.%; c. Thermoplastic elastomer in an amount in a range of 2.5 6.5 wt.%; and d. Metal carbonate in an amount in a range of 1.0 8.0 wt.%; and
  • the weight percentages (wt.%) are with respect to the total weight of the composition.
  • the PPS composition according to the present invention comprises 36 71.5 wt.% of a polyphenylene sulphide (PPS), relative to the total weight of the composition, next to glass fibres, impact modifier and a metal carbonate, and optionally further additives.
  • the amount of the PPS may vary over the whole range of 36 71.5 wt.%, and suitably is, for example, 39 wt.%, 46, wt.% 52 wt.%, 57 wt.%, or 63 wt.%.
  • the amount of the PPS is in the range of 40 70 wt.%, more preferably in the range of 42.5 67.5 wt.%, even more preferably in the range of 45 65 wt.%, relative to the total weight of the composition.
  • Polyphenylene sulphide (PPS) belongs to the group of organic polymers known as polyarylene sulphides, which consist of structural units, herein also referred to as repeat units, made up by aromatic rings linked by sulphides.
  • the polyphenylene sulphide (PPS) present in the composition according to the invention is a polymer comprising at least 50 mole%, preferably at least 70 mole%, and more preferable at least 90 mole% of p-phenylene sulphide repeat units of formula:
  • the mole% is relative to the total molar amount of repeat units in the PPS.
  • PPS containing at least at least 50 mole% of p-phenylene sulphide repeat units impart sufficient mechanical properties to the compositions according to the invention for general applications, whereas those with at least 70 mole% of p- phenylene sulphide repeat units impart also sufficient thermal stability and chemical resistance.
  • the remainder of repeat units in the PPS may be selected of other structural units, aromatic rings and linked by sulphides. These may be either functionalized or non-functionalized, or a combination thereof.
  • 50 mole% or less, respectively preferably 30 mole% or less, relative to the total molar amount of repeat units in the PPS, and more preferably 10 34565-WO-PCT[2] - 8 - mole% or less of the repeat units present in the PPS may be chosen from those which have the following structural formulae: , , , This group is herein addressed as structural units without functional groups, or non-functional structural units.
  • the PPS may comprise, preferably in small amounts, other structural units made up of aromatic rings bearing a functional group and linked by sulphides.
  • Such structural units are herein referred to as functionalized structural units.
  • the functional group can be selected from the group consisting of an amino group, a carboxyl group, a hydroxyl group, an acid anhydride group, an isocyanate group, an epoxy group, a silanol group, and an alkoxysilane group.
  • the amount of such other 34565-WO-PCT[2] - 9 - structural groups, if present at all, is preferably low, and suitably in the range of 0 5.0 mole%, more particular 0.01 1.0 mole%.
  • the mole% is relative to the total molar amount of repeat units in the PPS.
  • the amount of structural units within the composition without functional groups is reduced accordingly.
  • the PPS comprises at least 70 mole% of p- phenylene sulphide repeat units of formula . 30 mole% or less of non-functionalized repeat units chosen from the group having the following structural formulae: , , , , 34565-WO-PCT[2] - 10 - and 0 5.0 mole% structural units with functional groups, wherein the mole percentages (mole%) are relative to the total molar amount of repeat units in the PPS.
  • Processes for the manufacture of PPSs which can be employed according to the invention are known in the art. They can all be employed.
  • One such a process comprises heating an alkali metal sulphide, in most cases sodium sulphide hydrate, in a polar solvent in order to remove the water of hydration therefrom, followed by the addition of a dihalogenated aromatic compound, in particular p-dichlorobenzene, and polymerisation at higher temperature.
  • the PPS is subjected to a post- treatment by a deionizing purification and/or washing, as known in the art, to reduce achieve a low ionic species level, such as a low sodium content.
  • PPS having a low halogen content, suitably below 2000 ppm, preferably below 1500 ppm.
  • the corresponding preferred composition is also low in halogen content.
  • the PPS composition according to the invention comprises less than 900 ppm of chlorine or bromine and less than 1500 ppm of total halogens, relative to the total weight of the composition.
  • the composition complies with the industry standard for halogen-free materials as defined by emical Commission, Restriction Use of Halogen (IEC 61249-2- , while it still has good flame retardancy properties.
  • the molecular weight of the PPS employed in the composition according to the invention may vary within wide measures.
  • the PPS may have a relatively low molecular weight, and be prepared by known processes, such as that disclosed in U.S. Pat. No.3,354,129; or have a relatively high molecular weight, and can be prepared by known processes, such as that disclosed in U.S. Pat. No. 3,919,177.
  • the PPS may be linear or branched.
  • Substantially linear PPS of relatively high molecular weight can be obtained by addition of known agents for increasing the molecular weight (water, esters, anhydrides and alkali metal carboxylates and sulphonates, etc.) to the polycondensation mixture.
  • Branched PPS can be obtained by, for example, oxidative after-treatment.
  • the PPS employed in the invention has a melt flow rate in the range of 5 10,000 g/10 min, preferably in the range of 10 2,000 g/10 min, more preferably in the range of 50 1,000 g/10, determined according to ISO 1133-1-2022 at a temperature of 316 °C under a 5-kg load.
  • the composition according to the present invention comprises 25 45 wt.% of glass fibres.
  • the glass fibres may be any kind of glass fibres suitable for use in PPS compositions. It may vary in glass composition, fibre length and fibre diameter, and/or fibre cross section.
  • the glass fibres may also be pre-treated with a sizing and/or a coupling agent suitable for PPS glass fibre reinforcement. Such glass fibres are known in the art.
  • the composition of the glass in the glass fibres may be that of, for example, E-glass, A-glass, C-glass E-CR glass, R-glass or S-glass.
  • E-glass is aluminium borosilicate glass with less than 1% w/w alkali oxides.
  • A-glass is alkali-lime glass with little or no boron oxide.
  • E-CR-glass is glass with electrical/chemical resistance; and comprises aluminium-lime silicate with less than 1% wt.% of alkali oxides.
  • C-glass is alkali-lime glass with high boron oxide content.
  • D-glass is borosilicate glass, named for its low dielectric constant.
  • R-glass is aluminium silicate glass without MgO but high in CaO content, used for high reinforcement requirements;
  • S-glass is aluminium silicate glass without CaO but with high MgO content, having high tensile strength and modulus.
  • the glass fibres in the composition according to the invention are of E-glass.
  • the glass fibres suitably have a circularly shaped cross section.
  • the glass fibres may also have a cross section with other shapes, such as, for example, oblong, flat, ellipsoid, and so on.
  • the glass fibres used for the preparation of the composition suitably has a number average fibre diameter in the range of 5 20 , preferably in the range of 6
  • the glass fibres used for the preparation of the composition suitably are in the form of a roving, or in the form of chopped strands, for example, chopped strand with a number average fibre length in the range of 2 10 mm, preferably in the range of 3 6 mm.
  • Such glass fibres are available from companies like OWENS CORNING, PPG and JUSHI.
  • the number average length of the glass fibres in the composition according to the invention suitably is in the range of 20 range of 40 350 e range of 60 Within the range of 25 45 wt.% of glass fibres, the amount may be freely varied.
  • the of glass fibres in the composition according to the invention suitably 34565-WO-PCT[2] - 12 - is, for example, 28 wt.%, or 30 wt.%, or 35 wt.%, or 40 wt.%, or 42 wt.%.
  • the amount of glass fibres is in the range of 28 42 wt.%, more preferably 30 40 wt.%, relative to the total weight of the composition.
  • Thermoplastic elastomer comprises as an essential component 2.5 6.5 wt.% of a thermoplastic elastomer.
  • a thermoplastic elastomer is herein understood a thermoplastic material having rubber-like properties. Such a material is melt-processable, as applies for other thermoplastic materials, whereas it is able to regain substantially its original shape when a load is removed from the material, as applies for cross-linked rubber materials.
  • the thermoplastic elastomer in the composition according to the present invention can be any thermoplastic elastomer suitable for use as an impact modifier in PPS, either when being used alone, or in combination with another thermoplastic elastomer in the composition.
  • the thermoplastic elastomer suitably is selected from the group consisting of polyolefin-based elastomers, styrene/butadiene/styrene block- copolymers, polyamide block-copolymers and polyester block-copolymers, and any combinations thereof. Among these, polyolefin-based elastomers are preferred.
  • the polyamide block-copolymer suitably is a poly(ether-amide) block-copolymers or a poly(ester-amide) block-copolymer.
  • the polyester block-copolymer suitably is a poly(ether-ester) block-copolymer.
  • non- functionalized polyolefin copolymers as well as functionalized polyolefin copolymers and combinations thereof can be used.
  • copolymer copolymer understood a polymer derived from at least a first olefinic monomer and at least a second monomer different from the first olefinic monomer.
  • the second monomer can be either a second olefinic monomer, or a non-olefinic monomer, or a combination thereof.
  • the non-olefinic monomer may be another unsaturated monomer, which may be copolymerized together with the first olefinic monomer, and optionally a second olefinic monomer, thereby together forming a polyolefin backbone comprising repeat units derived from the unsaturated monomer, the first olefinic monomer, and optionally the second olefinic monomer.
  • the polyolefin copolymer may also have a polyolefin backbone comprising repeat units derived from the first olefinic monomer, and optionally the second olefinic monomer, the polyolefin backbone then being modified 34565-WO-PCT[2] - 13 - with the non-olefinic monomer.
  • another unsaturated monomer may be grafted onto polyolefin backbone, thereby forming the polyolefin copolymer.
  • the thermoplastic elastomer comprises at least a polyolefin-based elastomer, optionally combined with a second thermoplastic elastomer.
  • thermoplastic elastomer suitably a block-copolymer, a polyamide block-copolymer, or a polyester block-copolymer, or a combination thereof is used.
  • the polyolefin-based elastomer preferably comprises at least a functionalized polyolefin copolymer.
  • the ratio by weight of functionalized polyolefin copolymer to the second thermoplastic elastomer is at least 50:50, more preferable at least 75:25, and most preferred at least 90:10.
  • the functionalized polyolefin copolymer and the second thermoplastic elastomer are preferably pre-compounded prior to addition and combination with the PPS. Such pre- compounding prior to addition is advantageous for the impact and strain at break properties of the resulting PPS composition.
  • the thermoplastic elastomer comprises a functionalized polyolefin copolymer and a non-functionalized polyolefin copolymer.
  • the ratio of the functionalized polyolefin copolymer to the non-functionalized polyolefin copolymer by weight is suitably in the range of 20:80 - 90:10. The ratio may also be below 20:80, or above 90:10.
  • the ratio is at least 40:60, more preferable at least 50 : 50. Also preferably, the ratio is at most 85:15, more preferable at most 80:20.
  • a functionalized polyolefin copolymer is herein understood a copolymer comprising a polyolefin backbone modified with functional groups.
  • the polyolefin backbone suitably is a copolymer of different olefin nic monomers, in -olefinic monomers with 2 -olefinic monomers include ethylene, propylene, 1-butene (butylene), isobutylene, 1-pentene, 1- hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene, 1-hexadecene, 1-octadecene, and 4-methyl-1-pentene.
  • the polyolefin backbone preferably is a copolymer of two olefins selected from ethylene, propylene and butylene; or a copolymer of ethylene, propylene and butylene; or a copolymer of at least one olefin selected from ethylene, -olefinic monomer with 4 20 carbon atoms.
  • ethylene- -olefin copolymers and propylene- -olefin copolymers are preferred.
  • ethylene in the ethylene- -olefin copolymers is suitably present in an in amount of at least 20 mole%, more preferably at least 40 mole%.
  • the mole% is relative to the total 34565-WO-PCT[2] - 14 - molar amount of olefinic monomers and other unsaturated monomers in the polyolefin backbone.
  • these ethylene- -olefin copolymers with one or more C3-C12 - olefinic monomers and in particular ethylene-butylene copolymers are more preferred.
  • the polyolefin copolymer may comprise monomeric units derived from unsaturated monomers other than olefinic monomers, including, for example, an -unsaturated carboxylic acid alkyl ester, a diene or an aromatic monomer.
  • unsaturated monomers other than olefinic monomers including, for example, an -unsaturated carboxylic acid alkyl ester, a diene or an aromatic monomer.
  • Examples -unsaturated carboxylic acid alkyl esters suitably included in the polyolefin copolymer are 2-ethylhexylacrylate and butylmethacrylate.
  • diene component unit suitably comprised in the polyolefin copolymer
  • diene component unit include unconjugated diene components such as 1,4-hexadiene, dicyclopentadiene, 5-ethylidene-2- norbornene, and 2,5-norbornadiene; and conjugated diene components such as butadiene, isoprene and piperylene.
  • aromatic component unit that may be comprised in the polyolefin copolymer include styrene.
  • Another unsaturated monomer is suitably present, if at all, in an amount of at most 20 mole%, preferably at most 10 mole%, and most preferred 0 5.0 mole%.
  • the mole% is relative to the total molar amount of olefinic monomer and other unsaturated monomers in the polyolefin backbone.
  • Polyolefins comprising other unsaturated monomer copolymerized in combination with olefinic monomer, functionalized polyolefin copolymer comprising a polyolefin backbone comprising unsaturated monomer copolymerized are known in the art.
  • the functionalized polyolefin copolymer has a polyolefin backbone and modified with functional groups. Examples of suitable functional groups include acid groups, salts thereof, anhydride groups, epoxy groups and glycidyl groups.
  • the functionalized polyolefin copolymer used in the present invention suitable is an anhydride-modified polyolefin, an acid-modified polyolefin, an acidic salt- modified polyolefin, an epoxy-modified polyolefin, or a glycidyl-modified polyolefin, or any combination thereof.
  • the acid-modified polyolefin copolymer can be obtained by acid- modifying a polyolefin copolymer with an unsaturated carboxylic acid or an acid anhydride thereof.
  • Examples of the unsaturated carboxylic acid or the acid anhydride thereof include maleic acid, fumaric acid, itaconic acid, acrylic acid, meth acrylic acid, cis-4-cyclohexen-1,2-dicarboxylic acid, maleic anhydride, itaconic anhydride, and cis-4- cyclohexen-1,2 dicarboxylic acid anhydride.
  • maleic anhydride or itaconic anhydride is preferred, and maleic anhydride is more preferred.
  • Examples of epoxy functional monomers include, but are not limited to, glycidyl acrylate and glycidyl methacrylate.
  • the functionalization can be in the polyolefin backbone, or in side chains.
  • the functional groups may be incorporated in the polyolefin backbone by adding functional group bearing monomers during copolymerization with olefinic monomers, or may be incorporated by post-polymerization functionalization, such as by grafting functional monomers onto the polyolefin backbone.
  • the amount of the modifying functional groups in the functionalized polyolefin copolymer may vary.
  • the amount of the functional groups can be expressed as functional modification amount, at least 0.25 wt.%, or at most 10 wt.%, preferably 0.3 5.0 wt.%, more preferable 0.4 3.0 wt.% of maleic anhydride, relative to the total weight of the functionalized polyolefin copolymer.
  • the functionalized polyolefin copolymer typically has a glass transition temperature (Tg) well below 0 °C.
  • Tg glass transition temperature
  • the functionalized polyolefin copolymer has a Tg of at most -40 °C, preferably at most -50 °C, and more preferable at most -60 °C.
  • Tg is measured by the method according to ISO 11357-2:2020, with a heating ramp of 10°C/minute.
  • a low Tg is preferred from the viewpoint of mechanical properties at low temperature.
  • the functionalized polyolefin copolymer typically has a density well below 1 g/cm 3 .
  • the functionalized polyolefin copolymer has a density of at most 0.95 g/cm 3 , preferably at most 0.90 g/cm 3 , and more preferable at most 0.85 g/cm 3 .
  • the density is measured by the method according to ASTM D1505-03.
  • a low density is preferred from the viewpoint of mechanical properties at low temperature.
  • the functionalized polyolefin copolymer typically has a Shore A hardness well below 100.
  • the functionalized polyolefin copolymer has a Shore A hardness of at most 90, preferably at most 80, and more preferable at most 75.
  • the Shore A hardness is measured by the method according to ASTM D2240- 15.
  • a low Shore A hardness is preferred from the viewpoint of mechanical properties at low temperature.
  • the non-functionalized polyolefin copolymer can be, for example, a polyolefin copolymer of two or more olefinic monomers or a polyolefin copolymer of an olefinic monomer and another non-functional unsaturated monomer.
  • non- functionalized polyolefin copolymers are the same as the unmodified polyolefin copolymers used for the backbones in the functionalized polyolefin copolymer as mentioned herein above.
  • the non-modified polyolefin is selected from polyethylene, polypropylene, ethylene- -olefin copolymer and propylene- -olefin 34565-WO-PCT[2] - 16 - copolymer.
  • these ethylene- -olefin copolymers with one or more C3 C12 - olefinic monomers and in particular ethylene-butylene copolymers are more preferred.
  • the non-functionalized polyolefin copolymer suitably has a glass transition temperature (Tg) well below 0 °C.
  • Tg glass transition temperature
  • the Tg of the non-functionalized polyolefin copolymer is at most -40°C, preferably at most -50°C, and more preferable at most -60 °C.
  • the Tg is measured by the method according to ISO 11357- 2:2020, with a heating ramp of 10°C/minute.
  • a low Tg is preferred from the viewpoint of mechanical properties at low temperature.
  • the functionalized polyolefin copolymer in the composition according to the invention is suitably present in an amount in a range from 2.0 wt.% up to and including at most 6.5 wt.%, relative to the total weight of the composition.
  • the amount of functionalized polyolefin copolymer is in the range of 2.5 5.5 wt.%, more particular 3.0 5.0 wt.%.
  • the non-functionalized polyolefin copolymer is suitably present, if at all, in an amount in a range from 0 wt.% up to and including at most 4.0 wt.%, relative to the total weight of the composition.
  • the amount of non- functionalized polyolefin copolymer is in the range of 0.5 3.0 wt.%, more particular 1.0 2.0 wt.%.
  • the total amount of thermoplastic elastomer is in the range of 2.5 6.5 wt.%, or in a more restricted range as stipulated elsewhere herein.
  • the weight percentages (wt.%) are all relative to the total weight of the composition.
  • the total amount of thermoplastic elastomer is in the range of 3.0 6.0 wt.%, more preferred in the range of 3.0 5.8 wt.%, relative to the total weight of the composition.
  • the composition comprises 3.0 6.0 wt.%, even more particular 3.0 5.8 wt.%, of a combination of a functionalized polyolefin copolymer and a non-functionalized polyolefin copolymer. It is noted that the amount refers to the total of these copolymers.
  • Metal carbonate The metal carbonate can be represented by the formula Mx(CO3)y, wherein M represent a metallic cation with a formal charge of either +1, or +2, or +3, and CO3 represents the carbonate anion with a formal charge of -2.
  • the metal carbonate is a metal carbonate of a Group I element, or a metal carbonate of a Group II element, or a metal carbonate from metal elements like zinc, iron and aluminium.
  • metal carbonates of a Group I elements are lithium carbonate (Li2CO3), sodium carbonate (Na2CO3), and potassium carbonate (K 2 CO 3 ).
  • metal carbonates of a Group II elements are calcium carbonate (CaCO3) and magnesium carbonate (MgCO3).
  • Examples of other carbonates are zinc carbonate (ZnCO3), iron carbonate Fe2(CO3)3 and aluminium carbonate (Al2(CO3)3).
  • the metal carbonate may be a metal carbonate from a single metal element, or a metal carbonate from different metal elements or a mixture of different metal carbonates, or any combination thereof.
  • the metal carbonate is chosen from a metal carbonate of a Group I element, a metal carbonate of a Group II element or a metal carbonate of zinc, iron or aluminium, or any combination thereof.
  • the metal carbonate comprises a metal carbonate of a Group I element or a metal carbonate from a Group II element; or a combination thereof.
  • the metal carbonate comprises a metal carbonate from a Group II element; preferably the amount thereof is at least 50 wt.%, more preferable at least 75 wt.%, even more preferable at least 90 wt.%, relative to the total weight of metal carbonate.
  • the metal carbonate comprises calcium carbonate; preferably the amount thereof is at least 50 wt.%, more preferable at least 75 wt.%, even more preferable at least 90 wt.%, relative to the total weight of metal carbonate.
  • Most preferred the metal carbonate consists of calcium carbonate.
  • the metal carbonate in the composition according to the invention may consist of particles having different sizes. Typically, these particles will have a typically a particle size distribution, comprising smaller particles next to larger particles.
  • the number and size of larger particles are limited, compared to those of the smaller particles.
  • less than 10 % of the total number of metal carbonate particles have a size of more than 40 micrometre ( ⁇ m), preferably of more than 20 ⁇ m, more preferable of more than 10 ⁇ m; meanwhile, 90 % or more of the total number of metal carbonate particles have a size of at most 40 micrometre ( ⁇ m), preferably of at most 20 ⁇ m, more preferable of at most 10 ⁇ m.
  • less than 5 % of the total number of metal carbonate particles have a size of more than 20 micrometre ( ⁇ m), preferably of more 34565-WO-PCT[2] - 18 - than 15 ⁇ m, more preferable of more than 10 ⁇ m, 95 % or more of the total number of metal carbonate particles have a size of at most 20 micrometre ( ⁇ m), preferably of at most 15 ⁇ m, more preferable of at most 10 ⁇ m.
  • the sizes of the metal carbonate particles is determined from (SEM) pictures made of the surface of a cross section of a part or pellet made from the PPS composition.
  • the metal carbonates can have different and irregular shapes, with variable length and width.
  • the metal carbonate is present in an amount in the range of 1.0 8.0 wt.%.
  • the amount is at least 2.0 wt.%, more preferable at least 3.0 wt.%, and more preferred at least 4.0 wt.%.
  • the advantage of a higher amount of metal carbonate is that the flame retardancy is even better. This can be seen from shorter burning times in the UL94 test.
  • the amount of metal carbonate is at most 7.0 wt.%, more preferable at most 6.0 wt.%.
  • the amount of metal carbonate is in the range of 2.0 7.0 wt.%, more preferable in the range of 3.0 6.0 wt.%.
  • the weight percentage (wt.%) is with respect to the total weight of the composition.
  • the advantage of the amount of metal carbonate in the preferred ranges is that a better balance in properties in terms of flame retardancy, impact properties and elongation at break is obtained.
  • the composition according to the invention may comprise as a further component one or more additives.
  • the additive, or additives are suitably selected from auxiliary additives for PPS compositions, and can be used at levels typical in the art, and suitably at levels not detrimental to the effects of the present invention.
  • the combined amount of additives, if present at all, suitably is in the range of 0 10 wt.%, more particularly in the range of 0.01 5.0 wt.%, for example in the range of 0.1 3.0 wt.%, relative to the total weight of the composition.
  • the combined amount of further additives is at most 5.0 wt.%
  • the amount of PPS is in the range of 40 - 70 wt.%, relative to the total weight of the composition.
  • the PPS composition according to this preferred embodiment of the present invention consists of: 34565-WO-PCT[2] - 19 - a. 40 - 70 wt.% of polyphenylene sulphide (PPS) b. 25 45 wt.% of glass fibres c. 2.5 6.5 wt.% of thermoplastic elastomer d. 1.0 8.0 wt.% of metal carbonate; and e. 0 5.0 wt.% of further additives.
  • PPS polyphenylene sulphide
  • the weight percentages (wt.%) are with respect to the total weight of the composition and the sum of the weight percentages for the listed components a-e is 100 wt.%.
  • the PPS composition consists of : a. 45 - 65 wt.% of polyphenylene sulphide (PPS b. 28 42 wt.% of glass fibres c. 3.0 6.0 wt.% of thermoplastic elastomer d. 2.0 7.0 wt.% of metal carbonate; and e. 0 5.0 wt.% of further additives, wherein the weight percentages (wt.%) are with respect to the total weight of the composition and the sum of the listed amounts is 100 wt.%. More preferably the combined amount of further additives is at most 2.5 wt.%, even more preferably at most 2.0 wt.%, relative to the total weight of the composition.
  • Useful additives for the PPS composition of the present invention include, but are not limited to: dyes, colorants and pigments; for example: nigrosine, carbon black, cadmium sulphide and phthalocyanine; antistatic agents; for example: alkyl sulphate type anionic antistatic agents, quaternary ammonium salt type cationic antistatic agents and non-ionic antistatic agents; stabilizers; for example light stabilizers, (for example: UV absorbers), antioxidants, heat stabilizers, (for example: hindered phenol-based stabilizers, thioether-based stabilizers, hydroquinone-based stabilizers and phosphite- based stabilizers) and weathering agents (for example: resorcinol, salicylate, benzotriazole, benzophenone and hindered amine); processing aids; for example mold release agents and lubricants; examples thereof are montanic acid and its metal salts, esters, and half esters, stearyl alcohol,
  • the PPS composition comprises at least a silane-based coupling agent.
  • a silane-based coupling agent is herein understood a silicon compound that comprises an organofunctional group bonded to a silicon atom, and hydrolysable groups bonded to the silicon.
  • the hydrolysable group generally is alkoxy, acyloxy, halogen, or amine.
  • a reactive silanol group is formed, which can condense with other silanol groups, for example, those on the surface of siliceous fillers, to form siloxane linkages, whereas stable condensation products are also formed with other oxides such as those of aluminum, zirconium, tin, titanium, and nickel.
  • the organofunctional group is a nonhydrolyzable organic radical that may possess specific functionality.
  • Silane- based coupling agents are known in the art.
  • the silane-based coupling agent used in the composition according to the present invention is a silane compound selected from the group consisting of methacryloxy silane compounds, ureido silane compounds, epoxy silane compounds and amino silane compounds. These silanes have an organofunctional group comprising, respectively, an methacryloxy functionality, an ureido functionality, an epoxy functionality, or an amino functionality.
  • methacryloxy silane compounds include coupling agents such as -methacryloxypropyltrimethoxysilane, -methacryloxypropyltriethoxysilane, - methacryloxypropylmethyldiethoxysilane and - methacryloxypropylmethyldimethoxysilane.
  • ureido silane compounds include coupling agents such as -ureidopropyltriethoxy silane, -ureidopropyltrimethoxy silane and -(2-ureido ethyl)aminopropyltrimethoxysilane.
  • epoxy silane compounds include coupling agents such as -glycidoxypropyltrimethoxysilane, -glycidoxypropyltriethoxysilane, -(3,4- epoxycyclohexyl)ethyltrimethoxysilane, -glycidoxypropylmethyldiethoxysilane and - glycidoxypropylmethyldimethoxysilane.
  • An example of an amino- -aminopropyl triethoxyl silane 34565-WO-PCT[2] - 21 -
  • symbol beta is an amino- -aminopropyl triethoxyl silane.
  • the silane-based coupling agent is suitable present in an amount in the range of 0.01 2.0 wt.%, more preferably 0.1 1.0 wt.%, relative to the total weight of the composition.
  • the further additive comprised by the composition according to the invention comprises a silane-based coupling agent compound selected from the group consisting of methacryloxy silane compounds, ureido silane compounds, epoxy silane compounds and amino silane compounds, more preferably an amino silane.
  • the PPS composition according to the invention is obtainable by melt-mixing the PPS, glass fibres, thermoplastic elastomer and metal carbonate, and the optionally further additives, as mentioned herein above.
  • the additive or additives can be added into one of the components, such as the PPS, prior to admixing with the other components of the invention, or can be added during or after the admixing of components of the invention, for example prior to a molding process.
  • Method for preparing The present invention also relates to a process for the preparation of PPS composition, comprising the PPS, glass fibres, thermoplastic elastomer, metal carbonate; and optionally further additives in the amounts and with the parameters as specified herein above.
  • the process for preparing the PPS composition of the present invention is not particularly limited.
  • the PPS composition can be prepared by, for example, melt-mixing the various components to be added, as desired, by various methods known in the related art.
  • the PPS composition according to the invention may be prepared by any melt-mixing method and applying any known melt-mixing apparatus suitable for preparing thermoplastic PPS compositions.
  • melt-mixing herein refers to mixing the components while the PPS is in a melt stage.
  • the PPS composition may be prepared in, for example, a single screw extruder or a twin-screw extruder, a Banbury mixer, or a kneader or using a mixing roll.
  • a method of melt-mixing at a temperature of 280 380°C can be given, at which the raw materials are blended and melt kneaded.
  • Each raw material is supplied to a melt-mixing apparatus and there are no particular restrictions on the mixing order of the raw materials. Also a part of the raw materials can be melted and kneaded by the above method, and the remaining raw materials can be blended and melt-kneaded further on. As an example of such as a method is by melt-mixing a part of raw materials in a first section of a single-screw or twin-screw extruder, and adding the remaining raw materials using a side-feeder and melt-mixing these with the first part of raw materials in a second section of the single- screw or twin-screw extruder.
  • a small amount of additive component is kept separate, and, after the other components have been melt-mixed and pelletized by the above-described method, the small amount of additive component may be added to the pelletized material before molding and melt-mixed during the molding process.
  • the raw materials may also be pre-mixed.
  • the PPS composition can be obtained by charging the respective components simultaneously or sequentially into a mixing device such as a Henschel mixer, a V-type blender, a tumbler mixer, and a ribbon blender, heating and mixing them, and melt-kneading the mixture using, for example, a single-screw extruder, a multi-screw extruder, a kneader or a Banbury mixer.
  • a preferred method for preparing the PPS composition of the present invention is a method of melt-kneading with a twin-screw extruder.
  • the screw rotation speed is preferably controlled to be in a range of 200 400 rpm, more preferably in a range of 230 350 rpm.
  • the present invention also relates to a process for producing a molded article from the PPS composition, and to a molded article made of the PPS composition.
  • the process according to the present invention for producing a molded part or molded article comprises molding of a PPS composition according to the invention, and any particular or preferred embodiment thereof, as described herein 34565-WO-PCT[2] - 23 - above, into a preformed shape.
  • the process according to the present invention involves the use of a PPS composition according to the present invention, and for the process any known process suitable for molding PPS compositions can be used.
  • such a process comprises a melt-processing step, wherein the composition is heated to a temperature above the melting temperature of the PPS and a melt of the composition is formed.
  • a process may comprise the following steps: melt-processing step, wherein the composition is heated to a temperature above the melting temperature of the PPS and a melt of the composition is formed; a melt-shaping step, wherein the melt is shaping in a mold having a preformed shape; a step wherein the melt is cooled and solidified in the mold, thereby forming the molded part; and a demolding step, wherein molded part is removed from the mold.
  • the melt formed in the melt- processing step is transferred into the mold.
  • the composition may be heated in the mold to a temperature above the melting temperature of the PPS and a melt of the composition is formed, while being shaped in the mold, and subsequently be cooled and solidified in the mold.
  • the PPS composition of the present invention can be used for various molding processes such as injection molding, extrusion molding, blow molding and transfer molding, and is particularly suitable for injection molding.
  • a molded article made of the PPS composition according to the present invention and obtainable by a process as described above, has good mechanical properties, high elongation at break and high impact resistance and good flame retardancy properties. Therefore the molded article is eminently suited for various electrical and electronic applications. Meanwhile, the molded article is also suited for many other applications, including automobile parts and housing equipment parts.
  • molded parts which can be made of the PPS composition according to the present invention, include for example electrical and 34565-WO-PCT[2] - 24 - electronics applications, such as molded parts in 5G antenna radiator, notebook, tablet, insulated-gate bipolar transistor (IGBT), relay and capacitor and circuit breaker. Molded parts according to the invention can also be suitably employed in automotive applications, including for example E powertrain, Transport Management system (TMS), Battery system, fuel cell, Sensing and advanced driver assistance systems, such as housing for these.
  • Molded parts according to the invention can further suitably employed in food, water and appliance applications, such as for example home appliance, water meter, sanitary ware, condensing boiler, water pipe, liner for water pipe, kitchen utensils. Molded parts according to the invention can also suitably be employed in general industry applications, such as for example valve, pump, printer, steam regulator, robotics, power storage. Molded parts according to the invention can suitably be employed in medical applications, such as surgical tool, oxygenator component, health care atomizer.
  • PPS Acid washed linear PPS with Melt Flow Rate 500g/10min (at 316 °C, 5 kg), (ex Zhejiang NHU Specialty Materials Co., Ltd).
  • E-glass fibres chopped strand glass fiber, fiber length 3 mm, fiber diameter 10 ⁇ m (ex China Jushi Co., Ltd.).
  • TPE-I Epoxy-modified polyolefin copolymer (a copolymer of ethylene (E) and glycidyl methacrylate (GMA); GMA content: 8 mass%; Melt Flow Rate 5 g/10 min (at 190°C, 2.16 kg), melting point 104 °C) (ex SK Functional Polymer).
  • TPE-II non-modified polyolefin copolymer (a copolymer of ethylene (E) and octene-1 (OC); MFR 1.1 g/10 min at 190°C; Tg -50°C; (ex Borealis).
  • TPE-III Epoxy-modified polyolefin copolymer (a terpolymer of ethylene(E), methyl acrylate (MA) and glycidyl methacrylate (GMA); GMA content: 8 mass%; Melt Flow Rate 6 g/10 min (at 190°C, 2.16 kg), melting point 65 °C); (ex SK Functional Polymer).
  • Metal carbonate calcium carbonate (CaCO3); particle size distribution with median particle size (D50) 4 ⁇ m and D9810.2 ⁇ m ( ); (ex LianZhou DongNan New Materials CO., LTD). 34565-WO-PCT[2] - 25 - Mineral 1: Talc: Fineness 45 ⁇ m (test method GB/T15344 China standard) produced by Guangxi Longguang Talc Development Co., Ltd, LTD Mineral 2: CaSO4: Length 10-200 ⁇ m (90%) Diameter 1-4 ⁇ m (90%); (ex Jiangxi Fengzhu new materials technology CO., LTD).
  • Additive 1 Aminopropyltriethoxysilane (Amino coupling agent) (ex Nanjing Shuguang Silane Chemical Co., Ltd).
  • Additive 1 PPS based carbon black (CB) masterbatch (15 wt.% of CB in PPS) (ex Clariant Masterbatches SHG Ltd).
  • PPS compositions of the Examples and the Comparative Experiments were made from the ingredients as listed in Table 1.
  • the PPS compositions were prepared by uniformly mixing the PPS, the thermoplastics elastomer, and other additives as further required, with a tumbler, a Henschel mixer or the like, and melt kneading this in a Coperion STS35 twin screw extruder with a 35mm diameter with a cylinder temperature of 380° C. Further, among the components shown in Table 1 below, the glass fiber, calcium carbonate, talc and calcium sulfate were introduced into the extruder using a side feeder and melt kneaded. After extrusion, the materials produced were cooled and pelletized.
  • Test sample for Tensile Strength (TS) and Tensile Elongation at Break (EAB) properties ISO527 Type 1A specimen having a length of 150 mm, thickness of 4mm, and width of 20 mm
  • Test sample for Flexural Strength (FS) cut from ISO527 Type 1A specimen, having a length of 80 mm, thickness of 4mm, and width of 10 mm
  • Test sample for Notched Charpy Impact Strength (N-C) Cut from ISO527 Type 1A specimen, having length of 55 mm, thickness of 4 mm, and width of 10 mm, and having a notch, (0.25mm notched root radius, 2mm depth and 45 ° notch angle.
  • Test sample for Un-notched Charpy Impact Strength (UN-C): cut from ISO527 Type 1A specimen, having length of 55 mm, thickness of 4 mm, and width of 10 mm
  • Test sample for UL94 having a length of 125 mm, thickness of 0.8mm or 1.6mm, and width of 13 mm.
  • Measurements and test methods Tensile Strength (TS), and Tensile Elongation at Break (EAB) Tensile properties were tested with the test method according to ISO 527. The measurements were performed on the test samples for Tensile Strength (TS) and Tensile Elongation at Break (EAB) properties.
  • the testing temperature was 23°C and the testing speed was 5 mm/min.
  • Flexural Strength Flexural properties were tested with the test method according to ISO 178. This test was be performed on a 64 mm support span. The measurements were performed on test samples for Flexural Strength. The testing temperature was 23°C. and the testing speed was 2 mm/min. Notched Charpy Impact Strength and Un-notched Charpy Impact Strength Notched Charpy properties were tested with the test method according to ISO 179-1. The measurements were performed on the test samples for Notched Charpy Impact Strength. The testing temperature was 23 °C. Un-notched Charpy properties were tested with the test method according to ISO 179-1. The measurements were performed on the test samples for Un-notched Charpy Impact Strength. The testing temperature was 23 °C.
  • Flammability Flammability testing was done with the test method according to UL- 94 (20 mm Vertical Burning Test) using 0.8 mm or 1.6 mm thick test pieces, which were conditioned for either 48 hours at 23 °C and 50% relative humidity or 168 hours at 70 °C. Test results The test results show that the compositions of the Examples according to the Invention (E-1 E-6) and the Comparative Experiments (CE-A CE- 34565-WO-PCT[2] - 27 - G) are shown in Table 1.
  • compositions of the Examples according to the Invention all have good mechanical properties in terms of high tensile strength, and flexural strength, as well as a high elongation at break of at least 2.0 %, a high un-notched impact resistance of at least 55 J/m, and a UL94 flammability rating of V0 at both 0.8 mm thickness and 1.6 mm thickness.
  • the test results for the compositions of the Comparative Experiments either fail in the flammability test or have a lower elongation at break and/or a lower un-notched impact resistance.

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Abstract

The present invention relates to a PPS composition comprising 36 - 71.5 wt.% of polyphenylene sulphide (PPS); 25 - 45 wt.% of glass fibres; 2.5 - 6.5 wt.% of a thermoplastic elastomer; and 1.0 - 8.0 wt.% of a metal carbonate. The present invention also relates to a process for preparing the PPS composition, to a process for producing a molded article from the PPS composition, and to a molded article made of the PPS composition.

Description

34565-WO-PCT[2] - 1 - PPS COMPOSITION, PROCESS FOR PREPARATION, PROCESS FOR PRODUCING AN ARTICLE, AND ARTICLE MADE OF THE COMPOSITION The present invention relates to a polyphenylene sulphide-based composition (hereinafter referred to briefly as PPS composition). More particular, the invention is directed to a PPS composition comprising polyphenylene sulphide (PPS), glass fibres and an impact modifier, which has high mechanical strength, good ductility and good impact resistance, as well as good flame retardancy. The present invention also relates to a process for preparing the PPS composition, to a process for producing a molded article from the PPS composition, and to a molded article made of the PPS composition. Poly(phenylene sulphide), also regularly written as polyphenylene sulphide, (and hereinafter also abbreviated as PPS), is known to exhibit high heat resistance and thermal stability, very good chemical resistance, good mechanical properties such as rigidity and tensile strength, and good dimensional stability, as well as good flame retardancy and good processing properties. Because of its advantageous properties, PPS is widely used as an alternative material for metal materials mainly in automobile parts, electrical and electronic parts, and housing equipment parts. This includes in particular the use of fibre-reinforced PPS compositions, which have an even higher rigidity and tensile strength. However, PPS has the disadvantage of being brittle and hence having low impact strength. This generally also applies so for fibre-reinforced PPS compositions. To improve the impact toughness and reduce cost, impact-modified PPS compositions, comprising elastomeric copolymers, or comprising both fibre reinforcements and elastomeric copolymers, next to PPS, have been made and used. The elastomeric copolymers perform the function of impact modifier and are incorporated to improve the ductility and impact resistance. Ductility is the ability of a material to be deformed without losing toughness; toughness is the strength with which the material opposes rupture. Whereas impact modifiers improve the impact resistance, a general side effect is the reduction in rigidity and mechanical strength. Fibre reinforcements can compensate for the reduction in mechanical strength or even improve the mechanical strength of the impact-modified PPS composition. PPS compositions comprising PPS, elastomeric copolymers and fibre reinforcements are known in the art and are employed for multiple purposes. The elastomeric copolymer typically is a thermoplastic copolymer, generally linear or branched, that exhibit an elastic deformation when a force is applied. Among these, 34565-WO-PCT[2] - 2 - olefinic copolymers and functionalized derivates thereof are most frequently used. Among fibre reinforcements, glass fibres are mostly used. Compositions comprising polyphenylene sulphide (PPS), glass fibres and impact modifiers are described, for example, in EP0406553A2. A problem of such compositions is the bad flame retardancy. EP0406553A2 describes a PPS composition obtained by adding an olefin copolymer elastomer to a polyphenylene sulphide. The polyphenylene sulphide is prior melt-kneaded with a non-blocked type polyfunctional isocyanate compound. The composition is said to be excellent not only in impact resistance but also in aging resistance at high temperatures, and the composition can be advantageously used for moulding parts of automobile engines, parts for various machines, connectors for electric or electronic parts, bobbins and the like. The composition may comprise other components. Specifically mentioned are the optional addition of a polyamide resin or a bromine-containing flame retardant, whereas many examples with glass fibre reinforcement are given. More particular, glass fibres are generally blended in an amount of 40 wt.%, relative to 48-54 wt.% of the isocyanate modified PPS and 6-12 wt.% of the olefine copolymer elastomer. Two examples with a bromine-containing flame retardant are described, one with 4 wt.% flame retardant having a UL94 flame retardancy rating of V-1, the other, with double the amount of flame retardant, having a rating of V-0. These were compared with a corresponding impact-modified composition without flame retardant, having a HB flame retardancy rating. According to EP0406553, the deterioration of the flame retardancy of PPS is due to combustion of the elastomer(s) in the polyphenylene sulphide, whereas the addition of a bromine-containing flame retardant is effective in improving the flame retardancy. Most of the applications for PPS compositions require sufficient mechanical properties, including strength, toughness and ductility. Many of these applications, including electrical and electronic parts, and automotive parts like bus bar components, IGTB (insulated gate bipolar transistor) frames, also require sufficient flame retardant properties. From the viewpoint of environmental protection, the movement of halogen-free regulation has expanded rapidly, which in particular applies for the use of electrical and electronic parts. Since PPS is intrinsically flame retardant and essentially halogen free, the use of PPS compositions in this application area has strongly increased. However, a disadvantage of impact-modified fibre-reinforced PPS compositions is that the intrinsic flame retardancy of PPS is corroborated by the other 34565-WO-PCT[2] - 3 - components incorporated in the composition and the flame retardancy of the composition is typically insufficient for the more critical applications. In view of the increasing requirements on the performance of materials used in electrical and electronic parts and in automotive parts, there is a need for PPS compositions with good mechanical properties and impact strength and which also have good flame retardancy properties without making use of a halogen containing flame retardant. Therefore the object of the present invention is to provide a PPS composition comprising PPS, an impact modifier and fibre reinforcement, which has good mechanical properties and impact strength, and which also has good flame retardancy properties without the use of a halogen containing flame retardant. Surprisingly, this object has been achieved with the PPS composition according to the invention comprising, next to PPS, elastomeric copolymer and glass fibre reinforcement, a metal carbonate, each in an amount as specified below: a. 36 - 71.5 wt.% polyphenylene sulphide (PPS); b. 25 45 wt.% of glass fibres; c. 2.5 6.5 wt.% of a thermoplastic elastomer; and d. 1.0 8.0 wt.% of a metal carbonate. Herein the weight percentages (wt.%) are relative to the total weight of the PPS composition. The effect of the PPS composition according to the invention, comprising the metal carbonate next to the PPS, the elastomeric copolymer and the glass fibres in amounts within the specified ranges, is that the flame retardancy is improved while the mechanical properties and impact strength are retained at a high level. The inventors have shown with experiments that compositions according to the invention combine good mechanical properties, such as sufficient tensile strength, elongation at break and impact resistance, together with a flame retardancy rating of V0 at 0.8 mm as measured according to UL94. With too high a content in elastomeric copolymer, or too low a content in metal carbonate, the flame retardancy is not good, whereas with too high a content in metal carbonate, or too low a content in elastomeric copolymer, elongation at break and impact resistance are not good. Without wishing to be bound by theory, inventors believe that the presence of a metal carbonate in combination with the other components in amounts in the specified ranges, results in a synergistic effect on both 34565-WO-PCT[2] - 4 - the mechanical properties, including sufficient tensile strength, elongation at break, and impact resistance, as well as in sufficient flame retardancy. PPS compositions comprising metal carbonates in combination with PPS are known, however, the amounts of the metal carbonate often exceed 10 wt.% based on the total weight of the composition, and wherein the metal carbonate acts as a mineral filler to provide the physical and mechanical properties required for the final product or to reduce costs. Prior art documents reporting PPS compositions comprising metal carbonates, or comprising metal carbonates in combination with impact modifiers or fibre reinforcement next to PPS are, for example, the documents mentioned below. However, none of the prior art documents mentions the composition of the present invention nor reports about the synergistic effect on flame retardancy in combination with mechanical properties as elongation at break and impact resistance as according to the present invention. EP3650501A1 describes polyarylene sulphide resin compositions comprising a polyarylene sulphide resin and an inorganic filler treated with a specific sizing agent. The amount of filler is up to 100 parts by mass (pbm) relative to 100 pbm of the polyarylene sulphide resin. Examples of the inorganic filler include calcium carbonate and magnesium carbonate. Fibre reinforcement, such as glass fibres, and other components, such as polyolefin-based elastomers, can be optionally present. In a typical example, the composition comprises 35.5 wt.% of PPS, 30 wt.% GF, and 34 wt.% of CaCO3. The composition does not comprise any impact modifier. EP3650501A1 is silent about the about the problem solved by the present invention and about the effects according to the present invention. US6849697B2 describes PPS compositions essentially containing PPS, olefinic elastomers containing epoxy groups, and a crosslinking agent containing functional groups which are reactive towards the epoxy groups. These compositions are claimed to have improved impact strength. The compositions may also contain other ingredients in quantities not detrimental to the properties of these compositions. Among these, fillers and reinforcing materials are mentioned, such as, for example, glass fibres, which the composition may contain, in general, from 5 to 300% of the weight of PPS, and flame-retardant agents such as, for example, antimony salts, aryl chlorophosphates and chlorinated paraffins. JP6809083B2 describes PPS compositions for heat dissipating members. The compositions comprise PPS, whiskers having a number average fibre diameter in the range of 2 to 50 micrometre ( ), and spherical fillers having a number 34565-WO-PCT[2] - 5 - a spherical filler, magnesium carbonate, calcium carbonate, glass beads, silica and the like can be used. A thermoplastic elastomer can be blended as an optional component, if necessary. The blending ratio is not particularly limited as long as the claimed effects of JP6809083B2 are not impaired. Most examples are with MgCO3 with amounts between 9 and 27 wt.%. Herein the combined amounts of the whiskers and spherical fillers is typically in the range of 30 40 wt.%, relative to the total weight of the composition. JP6809083B2 is silent about the about the problem solved by the present invention and about the effects according to the present invention. CN108026369A describes polyarylene sulphide resin compositions, comprising a polyarylene sulphide resin, (100 parts by weight), fillers (65 300 pbw) and carbon black (more than 0.2 pbw, arithmetic mean diameter is 10~15 nm), that are claimed to have improved bending fracture strain and suppressed sensitivity for oil and fat. The composition may comprise granular fillers, among which mineral fillers, metal carbonates and metal sulphates, and fibrous fillers, among which glass fibres. to further improve toughness, the composition may comprise elastomers. As filler, preferably CN108026369A uses glass fibre, calcium carbonate or combinations thereof. In the many examples these fillers are typically used in relatively large amounts: relative to 100 pbw polyarylene sulphide; 35-147 pbw (20 40 wt.%) of glass fibres; 35-92 pbw (20 30 wt.%) of CaCO3; 0.46-5.2 pbw (1.5 - 2 wt.%) of CB; 3.5 22 pbw (2-6 wt.%) of an elastomer. CN108026369A reports the good anti-flammability properties of polyarylene sulphide, but is silent about the problems underlying the present invention as well as about the measures for the solution according to the present invention. JP6511785B2 describes a reinforced impact-modified PPS composition, and a resin moulded article thereof, that are claimed to have improved heat cycle resistance and self-tapping reliability. The composition of JP6511785B2 comprises PPS, a polyolefin or a combination of polyolefins and a combination of reinforcement fibres and filler. The combination of polyolefins comprises a functional group-containing olefin copolymer and a functional group- -olefin copolymer. The combination of reinforcement fibres and filler comprises glass fibres and calcium carbonate in a ratio of 2:1 to 7:1. The compositions in the examples of JP6511785B2 typically have a relative high content in CaCO3. Others are very low in content of the impact modifier. The patent focuses on increasing the friction to be overcome by the torque to be applied during tightening of a self-tapping screw. JP6511785B2 is silent about the problems underlying the present invention as well as about the measures for the solution according to the present invention. 34565-WO-PCT[2] - 6 - by polyphenylene sulphide resin has high heat resistance, mechanical properties, chemical resistance, dimensional stability, and flame retardancy. Therefore, it is widely used as an alternative material for metal materials mainly in automobile parts, electrical and electronic parts, and housing equipment parts, and the amount of use is also increasing. Among them, from the viewpoint of environmental protection in the use of electrical and electronic parts, the movement of halogen regulation has expanded rapidly, and the halogen content in a composition containing PAS resin is 900 ppm or JP6207809B2 describes a polyarylene sulphide resin composition having a reduced chlorine atom content, and a moulded article thereof, and a method for producing the polyarylene sulphide resin composition. The composition of -fibrous filler, and (C) a fibrous filler. Among the fillers, a long list of components is mentioned, among which carbonates, such as calcium carbonate and magnesium carbonate, and sulphates, such as calcium sulphate and barium sulphate. The composition of JP6207809B2 preferably further comprises an amorphous resin, such as polycarbonate resins and polyphenylene ether resins. The composition may further comprise other resins as long as the claimed effects are not impaired. Among these resins, polyolefin elastomers are mentioned, next to several other resins. Examples of the composition mentioned in JP6207809B2 comprise 35 wt.% of a polyarylene sulphide resin, 30 or 35 wt.% of CaCO3, 25 or 30 wt.% of glass fibres, and some examples further comprise 5 wt.% of an amorphous polyphenylene ether. Although JP6207809B2 mentions the flame retardancy properties of polyarylene sulphide, it is silent about the problems underlying the present invention let alone about the measures for the solution to that problem as according to the present invention. The PPS composition according to the present invention comprises the following components: a. Polyphenylene sulphide (PPS) in an amount in a range of 36 71.5 weight percentage (wt.%); b. Glass fibres in an amount in a range of 25 45 wt.%; c. Thermoplastic elastomer in an amount in a range of 2.5 6.5 wt.%; and d. Metal carbonate in an amount in a range of 1.0 8.0 wt.%; and Herein the weight percentages (wt.%) are with respect to the total weight of the composition. 34565-WO-PCT[2] - 7 - as used herein and expressed by a range that includes both the lower limit and the upper. Polyphenylene sulphide (PPS) The PPS composition according to the present invention comprises 36 71.5 wt.% of a polyphenylene sulphide (PPS), relative to the total weight of the composition, next to glass fibres, impact modifier and a metal carbonate, and optionally further additives. The amount of the PPS may vary over the whole range of 36 71.5 wt.%, and suitably is, for example, 39 wt.%, 46, wt.% 52 wt.%, 57 wt.%, or 63 wt.%. Preferably, the amount of the PPS is in the range of 40 70 wt.%, more preferably in the range of 42.5 67.5 wt.%, even more preferably in the range of 45 65 wt.%, relative to the total weight of the composition. Polyphenylene sulphide (PPS) belongs to the group of organic polymers known as polyarylene sulphides, which consist of structural units, herein also referred to as repeat units, made up by aromatic rings linked by sulphides. The polyphenylene sulphide (PPS) present in the composition according to the invention is a polymer comprising at least 50 mole%, preferably at least 70 mole%, and more preferable at least 90 mole% of p-phenylene sulphide repeat units of formula: Herein the mole% is relative to the total molar amount of repeat units in the PPS. PPS containing at least at least 50 mole% of p-phenylene sulphide repeat units impart sufficient mechanical properties to the compositions according to the invention for general applications, whereas those with at least 70 mole% of p- phenylene sulphide repeat units impart also sufficient thermal stability and chemical resistance. The remainder of repeat units in the PPS may be selected of other structural units, aromatic rings and linked by sulphides. These may be either functionalized or non-functionalized, or a combination thereof. Suitably, 50 mole% or less, respectively preferably 30 mole% or less, relative to the total molar amount of repeat units in the PPS, and more preferably 10 34565-WO-PCT[2] - 8 - mole% or less of the repeat units present in the PPS may be chosen from those which have the following structural formulae: , , , This group is herein addressed as structural units without functional groups, or non-functional structural units. The PPS may comprise, preferably in small amounts, other structural units made up of aromatic rings bearing a functional group and linked by sulphides. Such structural units are herein referred to as functionalized structural units. The functional group can be selected from the group consisting of an amino group, a carboxyl group, a hydroxyl group, an acid anhydride group, an isocyanate group, an epoxy group, a silanol group, and an alkoxysilane group. The amount of such other 34565-WO-PCT[2] - 9 - structural groups, if present at all, is preferably low, and suitably in the range of 0 5.0 mole%, more particular 0.01 1.0 mole%. Herein the mole% is relative to the total molar amount of repeat units in the PPS. For the PPS comprising other structural units comprising aromatic rings bearing a functional group, the amount of structural units within the composition without functional groups is reduced accordingly. In a specific embodiment, the PPS comprises at least 70 mole% of p- phenylene sulphide repeat units of formula . 30 mole% or less of non-functionalized repeat units chosen from the group having the following structural formulae: , , , , 34565-WO-PCT[2] - 10 - and 0 5.0 mole% structural units with functional groups, wherein the mole percentages (mole%) are relative to the total molar amount of repeat units in the PPS. Processes for the manufacture of PPSs which can be employed according to the invention are known in the art. They can all be employed. One such a process comprises heating an alkali metal sulphide, in most cases sodium sulphide hydrate, in a polar solvent in order to remove the water of hydration therefrom, followed by the addition of a dihalogenated aromatic compound, in particular p-dichlorobenzene, and polymerisation at higher temperature. Suitably, the PPS is subjected to a post- treatment by a deionizing purification and/or washing, as known in the art, to reduce achieve a low ionic species level, such as a low sodium content. Preferred is PPS having a low halogen content, suitably below 2000 ppm, preferably below 1500 ppm. Since metal carbonates are halogen-free, and shown to be effective flame retardants in the impact modified PPS composition according to the invention, the corresponding preferred composition is also low in halogen content. In a preferred embodiment the PPS composition according to the invention comprises less than 900 ppm of chlorine or bromine and less than 1500 ppm of total halogens, relative to the total weight of the composition. Thus, the composition complies with the industry standard for halogen-free materials as defined by emical Commission, Restriction Use of Halogen (IEC 61249-2- , while it still has good flame retardancy properties. This can be accomplished with the composition according to the invention by using a PPS having a low halogen content, as mentioned above, and making use of further additives therein, if at all, which are halogen-free or essentially halogen-free. The molecular weight of the PPS employed in the composition according to the invention may vary within wide measures. The PPS may have a relatively low molecular weight, and be prepared by known processes, such as that disclosed in U.S. Pat. No.3,354,129; or have a relatively high molecular weight, and can be prepared by known processes, such as that disclosed in U.S. Pat. No. 3,919,177. The PPS may be linear or branched. Substantially linear PPS of relatively high molecular weight can be obtained by addition of known agents for increasing the molecular weight (water, esters, anhydrides and alkali metal carboxylates and sulphonates, etc.) to the polycondensation mixture. Branched PPS can be obtained by, for example, oxidative after-treatment. Suitably, the PPS employed in the invention has a melt flow rate in the range of 5 10,000 g/10 min, preferably in the range of 10 2,000 g/10 min, more preferably in the range of 50 1,000 g/10, determined according to ISO 1133-1-2022 at a temperature of 316 °C under a 5-kg load. 34565-WO-PCT[2] - 11 - Glass fibres The composition according to the present invention comprises 25 45 wt.% of glass fibres. The glass fibres may be any kind of glass fibres suitable for use in PPS compositions. It may vary in glass composition, fibre length and fibre diameter, and/or fibre cross section. The glass fibres may also be pre-treated with a sizing and/or a coupling agent suitable for PPS glass fibre reinforcement. Such glass fibres are known in the art. The composition of the glass in the glass fibres may be that of, for example, E-glass, A-glass, C-glass E-CR glass, R-glass or S-glass. E-glass is aluminium borosilicate glass with less than 1% w/w alkali oxides. A-glass is alkali-lime glass with little or no boron oxide. E-CR-glass is glass with electrical/chemical resistance; and comprises aluminium-lime silicate with less than 1% wt.% of alkali oxides. C-glass is alkali-lime glass with high boron oxide content. D-glass is borosilicate glass, named for its low dielectric constant. R-glass is aluminium silicate glass without MgO but high in CaO content, used for high reinforcement requirements; S-glass is aluminium silicate glass without CaO but with high MgO content, having high tensile strength and modulus. Preferably, the glass fibres in the composition according to the invention are of E-glass. The glass fibres suitably have a circularly shaped cross section. The glass fibres may also have a cross section with other shapes, such as, for example, oblong, flat, ellipsoid, and so on. The glass fibres used for the preparation of the composition suitably has a number average fibre diameter in the range of 5 20 , preferably in the range of 6 The glass fibres used for the preparation of the composition suitably are in the form of a roving, or in the form of chopped strands, for example, chopped strand with a number average fibre length in the range of 2 10 mm, preferably in the range of 3 6 mm. Such glass fibres are available from companies like OWENS CORNING, PPG and JUSHI. The number average length of the glass fibres in the composition according to the invention, that is after compounding, extruding and pelletization, suitably is in the range of 20 range of 40 350 e range of 60 Within the range of 25 45 wt.% of glass fibres, the amount may be freely varied. The of glass fibres in the composition according to the invention suitably 34565-WO-PCT[2] - 12 - is, for example, 28 wt.%, or 30 wt.%, or 35 wt.%, or 40 wt.%, or 42 wt.%. Preferably, the amount of glass fibres is in the range of 28 42 wt.%, more preferably 30 40 wt.%, relative to the total weight of the composition. Thermoplastic elastomer The composition according to the present invention comprises as an essential component 2.5 6.5 wt.% of a thermoplastic elastomer. With a thermoplastic elastomer is herein understood a thermoplastic material having rubber-like properties. Such a material is melt-processable, as applies for other thermoplastic materials, whereas it is able to regain substantially its original shape when a load is removed from the material, as applies for cross-linked rubber materials. The thermoplastic elastomer in the composition according to the present invention can be any thermoplastic elastomer suitable for use as an impact modifier in PPS, either when being used alone, or in combination with another thermoplastic elastomer in the composition. The thermoplastic elastomer suitably is selected from the group consisting of polyolefin-based elastomers, styrene/butadiene/styrene block- copolymers, polyamide block-copolymers and polyester block-copolymers, and any combinations thereof. Among these, polyolefin-based elastomers are preferred. The polyamide block-copolymer suitably is a poly(ether-amide) block-copolymers or a poly(ester-amide) block-copolymer. The polyester block-copolymer suitably is a poly(ether-ester) block-copolymer. For the polyolefin-based elastomers, non- functionalized polyolefin copolymers as well as functionalized polyolefin copolymers and combinations thereof can be used. With the term copolymer copolymer understood a polymer derived from at least a first olefinic monomer and at least a second monomer different from the first olefinic monomer. The second monomer can be either a second olefinic monomer, or a non-olefinic monomer, or a combination thereof. The non-olefinic monomer may be another unsaturated monomer, which may be copolymerized together with the first olefinic monomer, and optionally a second olefinic monomer, thereby together forming a polyolefin backbone comprising repeat units derived from the unsaturated monomer, the first olefinic monomer, and optionally the second olefinic monomer. The polyolefin copolymer may also have a polyolefin backbone comprising repeat units derived from the first olefinic monomer, and optionally the second olefinic monomer, the polyolefin backbone then being modified 34565-WO-PCT[2] - 13 - with the non-olefinic monomer. For example, another unsaturated monomer may be grafted onto polyolefin backbone, thereby forming the polyolefin copolymer. Preferably, the thermoplastic elastomer comprises at least a polyolefin-based elastomer, optionally combined with a second thermoplastic elastomer. For such second thermoplastic elastomer suitably a block-copolymer, a polyamide block-copolymer, or a polyester block-copolymer, or a combination thereof is used. Where the polyolefin-based elastomer is combined with a second thermoplastic elastomer, the polyolefin-based elastomer preferably comprises at least a functionalized polyolefin copolymer. Also preferably, the ratio by weight of functionalized polyolefin copolymer to the second thermoplastic elastomer is at least 50:50, more preferable at least 75:25, and most preferred at least 90:10. The functionalized polyolefin copolymer and the second thermoplastic elastomer are preferably pre-compounded prior to addition and combination with the PPS. Such pre- compounding prior to addition is advantageous for the impact and strain at break properties of the resulting PPS composition. In a preferred embodiment of the invention, the thermoplastic elastomer comprises a functionalized polyolefin copolymer and a non-functionalized polyolefin copolymer. Herein, the ratio of the functionalized polyolefin copolymer to the non-functionalized polyolefin copolymer by weight is suitably in the range of 20:80 - 90:10. The ratio may also be below 20:80, or above 90:10. Preferably, the ratio is at least 40:60, more preferable at least 50 : 50. Also preferably, the ratio is at most 85:15, more preferable at most 80:20. With a functionalized polyolefin copolymer is herein understood a copolymer comprising a polyolefin backbone modified with functional groups. The polyolefin backbone suitably is a copolymer of different olefin nic monomers, in -olefinic monomers with 2 -olefinic monomers include ethylene, propylene, 1-butene (butylene), isobutylene, 1-pentene, 1- hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene, 1-hexadecene, 1-octadecene, and 4-methyl-1-pentene. The polyolefin backbone preferably is a copolymer of two olefins selected from ethylene, propylene and butylene; or a copolymer of ethylene, propylene and butylene; or a copolymer of at least one olefin selected from ethylene, -olefinic monomer with 4 20 carbon atoms. Herein, ethylene- -olefin copolymers and propylene- -olefin copolymers are preferred. Herein ethylene in the ethylene- -olefin copolymers, respectively propylene in the propylene- -olefin copolymers, is suitably present in an in amount of at least 20 mole%, more preferably at least 40 mole%. Herein the mole% is relative to the total 34565-WO-PCT[2] - 14 - molar amount of olefinic monomers and other unsaturated monomers in the polyolefin backbone. Among these ethylene- -olefin copolymers with one or more C3-C12 - olefinic monomers, and in particular ethylene-butylene copolymers are more preferred. The polyolefin copolymer may comprise monomeric units derived from unsaturated monomers other than olefinic monomers, including, for example, an -unsaturated carboxylic acid alkyl ester, a diene or an aromatic monomer. Examples -unsaturated carboxylic acid alkyl esters suitably included in the polyolefin copolymer are 2-ethylhexylacrylate and butylmethacrylate. Examples of the diene component unit suitably comprised in the polyolefin copolymer, include unconjugated diene components such as 1,4-hexadiene, dicyclopentadiene, 5-ethylidene-2- norbornene, and 2,5-norbornadiene; and conjugated diene components such as butadiene, isoprene and piperylene. Examples of the aromatic component unit that may be comprised in the polyolefin copolymer include styrene. Another unsaturated monomer is suitably present, if at all, in an amount of at most 20 mole%, preferably at most 10 mole%, and most preferred 0 5.0 mole%. Herein the mole% is relative to the total molar amount of olefinic monomer and other unsaturated monomers in the polyolefin backbone. Polyolefins comprising other unsaturated monomer copolymerized in combination with olefinic monomer, functionalized polyolefin copolymer comprising a polyolefin backbone comprising unsaturated monomer copolymerized are known in the art. The functionalized polyolefin copolymer has a polyolefin backbone and modified with functional groups. Examples of suitable functional groups include acid groups, salts thereof, anhydride groups, epoxy groups and glycidyl groups. Accordingly, the functionalized polyolefin copolymer used in the present invention suitable is an anhydride-modified polyolefin, an acid-modified polyolefin, an acidic salt- modified polyolefin, an epoxy-modified polyolefin, or a glycidyl-modified polyolefin, or any combination thereof. The acid-modified polyolefin copolymer can be obtained by acid- modifying a polyolefin copolymer with an unsaturated carboxylic acid or an acid anhydride thereof. Examples of the unsaturated carboxylic acid or the acid anhydride thereof include maleic acid, fumaric acid, itaconic acid, acrylic acid, meth acrylic acid, cis-4-cyclohexen-1,2-dicarboxylic acid, maleic anhydride, itaconic anhydride, and cis-4- cyclohexen-1,2 dicarboxylic acid anhydride. Among these, maleic anhydride or itaconic anhydride is preferred, and maleic anhydride is more preferred. Examples of epoxy functional monomers include, but are not limited to, glycidyl acrylate and glycidyl methacrylate. 34565-WO-PCT[2] - 15 - The functionalization can be in the polyolefin backbone, or in side chains. The functional groups may be incorporated in the polyolefin backbone by adding functional group bearing monomers during copolymerization with olefinic monomers, or may be incorporated by post-polymerization functionalization, such as by grafting functional monomers onto the polyolefin backbone. The amount of the modifying functional groups in the functionalized polyolefin copolymer may vary. The amount of the functional groups can be expressed as functional modification amount, at least 0.25 wt.%, or at most 10 wt.%, preferably 0.3 5.0 wt.%, more preferable 0.4 3.0 wt.% of maleic anhydride, relative to the total weight of the functionalized polyolefin copolymer. The functionalized polyolefin copolymer typically has a glass transition temperature (Tg) well below 0 °C. Suitably, the functionalized polyolefin copolymer has a Tg of at most -40 °C, preferably at most -50 °C, and more preferable at most -60 °C. Herein Tg is measured by the method according to ISO 11357-2:2020, with a heating ramp of 10°C/minute. A low Tg is preferred from the viewpoint of mechanical properties at low temperature. The functionalized polyolefin copolymer typically has a density well below 1 g/cm3. Suitably, the functionalized polyolefin copolymer has a density of at most 0.95 g/cm3, preferably at most 0.90 g/cm3, and more preferable at most 0.85 g/cm3. Herein the density is measured by the method according to ASTM D1505-03. A low density is preferred from the viewpoint of mechanical properties at low temperature. The functionalized polyolefin copolymer typically has a Shore A hardness well below 100. Suitably, the functionalized polyolefin copolymer has a Shore A hardness of at most 90, preferably at most 80, and more preferable at most 75. Herein the Shore A hardness is measured by the method according to ASTM D2240- 15. A low Shore A hardness is preferred from the viewpoint of mechanical properties at low temperature. The non-functionalized polyolefin copolymer can be, for example, a polyolefin copolymer of two or more olefinic monomers or a polyolefin copolymer of an olefinic monomer and another non-functional unsaturated monomer. Examples of non- functionalized polyolefin copolymers are the same as the unmodified polyolefin copolymers used for the backbones in the functionalized polyolefin copolymer as mentioned herein above. Preferably, the non-modified polyolefin is selected from polyethylene, polypropylene, ethylene- -olefin copolymer and propylene- -olefin 34565-WO-PCT[2] - 16 - copolymer. Among these ethylene- -olefin copolymers with one or more C3 C12 - olefinic monomers, and in particular ethylene-butylene copolymers are more preferred. The non-functionalized polyolefin copolymer suitably has a glass transition temperature (Tg) well below 0 °C. Suitably, the Tg of the non-functionalized polyolefin copolymer is at most -40°C, preferably at most -50°C, and more preferable at most -60 °C. Herein the Tg is measured by the method according to ISO 11357- 2:2020, with a heating ramp of 10°C/minute. A low Tg is preferred from the viewpoint of mechanical properties at low temperature. The functionalized polyolefin copolymer in the composition according to the invention is suitably present in an amount in a range from 2.0 wt.% up to and including at most 6.5 wt.%, relative to the total weight of the composition. Preferably, the amount of functionalized polyolefin copolymer is in the range of 2.5 5.5 wt.%, more particular 3.0 5.0 wt.%. The non-functionalized polyolefin copolymer is suitably present, if at all, in an amount in a range from 0 wt.% up to and including at most 4.0 wt.%, relative to the total weight of the composition. Preferably, the amount of non- functionalized polyolefin copolymer is in the range of 0.5 3.0 wt.%, more particular 1.0 2.0 wt.%. This all on the provision that the total amount of thermoplastic elastomer is in the range of 2.5 6.5 wt.%, or in a more restricted range as stipulated elsewhere herein. Herein the weight percentages (wt.%) are all relative to the total weight of the composition. In a preferred embodiment of the present invention, the total amount of thermoplastic elastomer is in the range of 3.0 6.0 wt.%, more preferred in the range of 3.0 5.8 wt.%, relative to the total weight of the composition. More particular, the composition comprises 3.0 6.0 wt.%, even more particular 3.0 5.8 wt.%, of a combination of a functionalized polyolefin copolymer and a non-functionalized polyolefin copolymer. It is noted that the amount refers to the total of these copolymers. Metal carbonate The metal carbonate can be represented by the formula Mx(CO3)y, wherein M represent a metallic cation with a formal charge of either +1, or +2, or +3, and CO3 represents the carbonate anion with a formal charge of -2. The symbols x and y represent integers, wherein x can have a value of 1 or 2, and y can have a value of 1 or 3, depending on the formal charge of the metallic cation. More particularly, with a metallic cation with a formal charge of +1, x = 2 and y = 1, and the metal carbonate can be represented by the formula M2CO3. With a metallic cation with a formal charge of +2, x = 1 and y = 1, and the metal carbonate can be represented by the formula MCO3. 34565-WO-PCT[2] - 17 - With a metallic cation with a formal charge of +3, x = 2 and y = 3 and the metal carbonate can be represented by the formula M2(CO3)3. Suitably, the metal carbonate is a metal carbonate of a Group I element, or a metal carbonate of a Group II element, or a metal carbonate from metal elements like zinc, iron and aluminium. Examples of metal carbonates of a Group I elements are lithium carbonate (Li2CO3), sodium carbonate (Na2CO3), and potassium carbonate (K2CO3). Examples of metal carbonates of a Group II elements are calcium carbonate (CaCO3) and magnesium carbonate (MgCO3). Examples of other carbonates are zinc carbonate (ZnCO3), iron carbonate Fe2(CO3)3 and aluminium carbonate (Al2(CO3)3). The metal carbonate may be a metal carbonate from a single metal element, or a metal carbonate from different metal elements or a mixture of different metal carbonates, or any combination thereof. Suitably, the metal carbonate is chosen from a metal carbonate of a Group I element, a metal carbonate of a Group II element or a metal carbonate of zinc, iron or aluminium, or any combination thereof. Preferably the metal carbonate comprises a metal carbonate of a Group I element or a metal carbonate from a Group II element; or a combination thereof. More preferable, the metal carbonate comprises a metal carbonate from a Group II element; preferably the amount thereof is at least 50 wt.%, more preferable at least 75 wt.%, even more preferable at least 90 wt.%, relative to the total weight of metal carbonate. Even more preferred the metal carbonate comprises calcium carbonate; preferably the amount thereof is at least 50 wt.%, more preferable at least 75 wt.%, even more preferable at least 90 wt.%, relative to the total weight of metal carbonate. Most preferred the metal carbonate consists of calcium carbonate. The metal carbonate in the composition according to the invention may consist of particles having different sizes. Typically, these particles will have a typically a particle size distribution, comprising smaller particles next to larger particles. Preferably, the number and size of larger particles are limited, compared to those of the smaller particles. In a preferred embodiment, less than 10 % of the total number of metal carbonate particles have a size of more than 40 micrometre (µm), preferably of more than 20 µm, more preferable of more than 10 µm; meanwhile, 90 % or more of the total number of metal carbonate particles have a size of at most 40 micrometre (µm), preferably of at most 20 µm, more preferable of at most 10 µm. In a preferred embodiment, less than 5 % of the total number of metal carbonate particles have a size of more than 20 micrometre (µm), preferably of more 34565-WO-PCT[2] - 18 - than 15 µm, more preferable of more than 10 µm, 95 % or more of the total number of metal carbonate particles have a size of at most 20 micrometre (µm), preferably of at most 15 µm, more preferable of at most 10 µm. Herein the sizes of the metal carbonate particles is determined from (SEM) pictures made of the surface of a cross section of a part or pellet made from the PPS composition. The metal carbonates can have different and irregular shapes, with variable length and width. With the size of a particle is herein understood the largest dimension of a particle as determined from the SEM picture. Methods for obtaining SEM pictures from filled polymeric materials are known in the art. In the PPS composition according to the invention, the metal carbonate is present in an amount in the range of 1.0 8.0 wt.%. Preferably, the amount is at least 2.0 wt.%, more preferable at least 3.0 wt.%, and more preferred at least 4.0 wt.%. The advantage of a higher amount of metal carbonate is that the flame retardancy is even better. This can be seen from shorter burning times in the UL94 test. Also preferably, the amount of metal carbonate is at most 7.0 wt.%, more preferable at most 6.0 wt.%. The advantage of a lower amount is that the impact properties and elongation at break are better retained. Preferably, the amount of metal carbonate is in the range of 2.0 7.0 wt.%, more preferable in the range of 3.0 6.0 wt.%. Herein the weight percentage (wt.%), is with respect to the total weight of the composition. The advantage of the amount of metal carbonate in the preferred ranges is that a better balance in properties in terms of flame retardancy, impact properties and elongation at break is obtained. Further additives The composition according to the invention may comprise as a further component one or more additives. The additive, or additives, are suitably selected from auxiliary additives for PPS compositions, and can be used at levels typical in the art, and suitably at levels not detrimental to the effects of the present invention. The combined amount of additives, if present at all, suitably is in the range of 0 10 wt.%, more particularly in the range of 0.01 5.0 wt.%, for example in the range of 0.1 3.0 wt.%, relative to the total weight of the composition. Preferably, the combined amount of further additives is at most 5.0 wt.%, and the amount of PPS is in the range of 40 - 70 wt.%, relative to the total weight of the composition. Accordingly, the PPS composition according to this preferred embodiment of the present invention consists of: 34565-WO-PCT[2] - 19 - a. 40 - 70 wt.% of polyphenylene sulphide (PPS) b. 25 45 wt.% of glass fibres c. 2.5 6.5 wt.% of thermoplastic elastomer d. 1.0 8.0 wt.% of metal carbonate; and e. 0 5.0 wt.% of further additives. Herein the weight percentages (wt.%) are with respect to the total weight of the composition and the sum of the weight percentages for the listed components a-e is 100 wt.%. In a more preferred embodiment, the PPS composition consists of : a. 45 - 65 wt.% of polyphenylene sulphide (PPS b. 28 42 wt.% of glass fibres c. 3.0 6.0 wt.% of thermoplastic elastomer d. 2.0 7.0 wt.% of metal carbonate; and e. 0 5.0 wt.% of further additives, wherein the weight percentages (wt.%) are with respect to the total weight of the composition and the sum of the listed amounts is 100 wt.%. More preferably the combined amount of further additives is at most 2.5 wt.%, even more preferably at most 2.0 wt.%, relative to the total weight of the composition. Useful additives for the PPS composition of the present invention, include, but are not limited to: dyes, colorants and pigments; for example: nigrosine, carbon black, cadmium sulphide and phthalocyanine; antistatic agents; for example: alkyl sulphate type anionic antistatic agents, quaternary ammonium salt type cationic antistatic agents and non-ionic antistatic agents; stabilizers; for example light stabilizers, (for example: UV absorbers), antioxidants, heat stabilizers, (for example: hindered phenol-based stabilizers, thioether-based stabilizers, hydroquinone-based stabilizers and phosphite- based stabilizers) and weathering agents (for example: resorcinol, salicylate, benzotriazole, benzophenone and hindered amine); processing aids; for example mold release agents and lubricants; examples thereof are montanic acid and its metal salts, esters, and half esters, stearyl alcohol, stearamide, calcium stearate, aluminium stearate, lithium stearate, calcium or magnesium stearate; crystal nucleating agents; for example: talc, silica, kaolin and clays; 34565-WO-PCT[2] - 20 - plasticizers: for example: p-octyl-oxybenzoate and N-butylbenzene sulfonamides; and coupling agents; for example: silane-based coupling agents; as well as combinations of additives mentioned. In a preferred embodiment of the invention, the PPS composition comprises at least a silane-based coupling agent. The advantage thereof is that the mechanical properties are enhanced. With a silane-based coupling agent is herein understood a silicon compound that comprises an organofunctional group bonded to a silicon atom, and hydrolysable groups bonded to the silicon. The hydrolysable group generally is alkoxy, acyloxy, halogen, or amine. Following hydrolysis, a reactive silanol group is formed, which can condense with other silanol groups, for example, those on the surface of siliceous fillers, to form siloxane linkages, whereas stable condensation products are also formed with other oxides such as those of aluminum, zirconium, tin, titanium, and nickel. The organofunctional group is a nonhydrolyzable organic radical that may possess specific functionality. Silane- based coupling agents are known in the art. Suitably, the silane-based coupling agent used in the composition according to the present invention is a silane compound selected from the group consisting of methacryloxy silane compounds, ureido silane compounds, epoxy silane compounds and amino silane compounds. These silanes have an organofunctional group comprising, respectively, an methacryloxy functionality, an ureido functionality, an epoxy functionality, or an amino functionality. Examples of methacryloxy silane compounds include coupling agents such as -methacryloxypropyltrimethoxysilane, -methacryloxypropyltriethoxysilane, - methacryloxypropylmethyldiethoxysilane and - methacryloxypropylmethyldimethoxysilane. Examples ureido silane compounds include coupling agents such as -ureidopropyltriethoxy silane, -ureidopropyltrimethoxy silane and -(2-ureido ethyl)aminopropyltrimethoxysilane. Examples of epoxy silane compounds include coupling agents such as -glycidoxypropyltrimethoxysilane, -glycidoxypropyltriethoxysilane, -(3,4- epoxycyclohexyl)ethyltrimethoxysilane, -glycidoxypropylmethyldiethoxysilane and - glycidoxypropylmethyldimethoxysilane. An example of an amino- -aminopropyl triethoxyl silane. 34565-WO-PCT[2] - 21 - Herein above, symbol beta. The silane-based coupling agent is suitable present in an amount in the range of 0.01 2.0 wt.%, more preferably 0.1 1.0 wt.%, relative to the total weight of the composition. Preferably, the further additive comprised by the composition according to the invention comprises a silane-based coupling agent compound selected from the group consisting of methacryloxy silane compounds, ureido silane compounds, epoxy silane compounds and amino silane compounds, more preferably an amino silane. The PPS composition according to the invention is obtainable by melt-mixing the PPS, glass fibres, thermoplastic elastomer and metal carbonate, and the optionally further additives, as mentioned herein above. For the preparation of the composition according to the invention, the additive or additives can be added into one of the components, such as the PPS, prior to admixing with the other components of the invention, or can be added during or after the admixing of components of the invention, for example prior to a molding process. Method for preparing The present invention also relates to a process for the preparation of PPS composition, comprising the PPS, glass fibres, thermoplastic elastomer, metal carbonate; and optionally further additives in the amounts and with the parameters as specified herein above. The process for preparing the PPS composition of the present invention is not particularly limited. The PPS composition can be prepared by, for example, melt-mixing the various components to be added, as desired, by various methods known in the related art. The PPS composition according to the invention may be prepared by any melt-mixing method and applying any known melt-mixing apparatus suitable for preparing thermoplastic PPS compositions. herein refers to melting the PPS, and the term melt-mixing herein refers to mixing the components while the PPS is in a melt stage. The PPS composition may be prepared in, for example, a single screw extruder or a twin-screw extruder, a Banbury mixer, or a kneader or using a mixing roll. As a representative example, a method of melt-mixing at a temperature of 280 380°C, can be given, at which the raw materials are blended and melt kneaded. 34565-WO-PCT[2] - 22 - Each raw material is supplied to a melt-mixing apparatus and there are no particular restrictions on the mixing order of the raw materials. Also a part of the raw materials can be melted and kneaded by the above method, and the remaining raw materials can be blended and melt-kneaded further on. As an example of such as a method is by melt-mixing a part of raw materials in a first section of a single-screw or twin-screw extruder, and adding the remaining raw materials using a side-feeder and melt-mixing these with the first part of raw materials in a second section of the single- screw or twin-screw extruder. As another example, a small amount of additive component is kept separate, and, after the other components have been melt-mixed and pelletized by the above-described method, the small amount of additive component may be added to the pelletized material before molding and melt-mixed during the molding process. The raw materials may also be pre-mixed. For example, the PPS composition can be obtained by charging the respective components simultaneously or sequentially into a mixing device such as a Henschel mixer, a V-type blender, a tumbler mixer, and a ribbon blender, heating and mixing them, and melt-kneading the mixture using, for example, a single-screw extruder, a multi-screw extruder, a kneader or a Banbury mixer. In particular, if a device having excellent kneading performance, such as a multi-screw extruder, a kneader, and a Banbury mixer is used, a high-quality PPS composition in which the respective components are more uniformly dispersed is obtained. A preferred method for preparing the PPS composition of the present invention is a method of melt-kneading with a twin-screw extruder. When melt- kneading with such a twin-screw extruder, the screw rotation speed is preferably controlled to be in a range of 200 400 rpm, more preferably in a range of 230 350 rpm. By controlling the rotation speed in the said range, a good balance in productivity and limitation of heat generation and decomposition of the polymers in the composition can be obtained. Molded parts and applications The present invention also relates to a process for producing a molded article from the PPS composition, and to a molded article made of the PPS composition. The process according to the present invention for producing a molded part or molded article comprises molding of a PPS composition according to the invention, and any particular or preferred embodiment thereof, as described herein 34565-WO-PCT[2] - 23 - above, into a preformed shape. The process according to the present invention involves the use of a PPS composition according to the present invention, and for the process any known process suitable for molding PPS compositions can be used. Typically, such a process comprises a melt-processing step, wherein the composition is heated to a temperature above the melting temperature of the PPS and a melt of the composition is formed. Such a process may comprise the following steps: melt-processing step, wherein the composition is heated to a temperature above the melting temperature of the PPS and a melt of the composition is formed; a melt-shaping step, wherein the melt is shaping in a mold having a preformed shape; a step wherein the melt is cooled and solidified in the mold, thereby forming the molded part; and a demolding step, wherein molded part is removed from the mold. Suitably, for the melt-shaping step, the melt formed in the melt- processing step is transferred into the mold. As an alternative, the composition may be heated in the mold to a temperature above the melting temperature of the PPS and a melt of the composition is formed, while being shaped in the mold, and subsequently be cooled and solidified in the mold. The PPS composition of the present invention can be used for various molding processes such as injection molding, extrusion molding, blow molding and transfer molding, and is particularly suitable for injection molding. A molded article made of the PPS composition according to the present invention and obtainable by a process as described above, has good mechanical properties, high elongation at break and high impact resistance and good flame retardancy properties. Therefore the molded article is eminently suited for various electrical and electronic applications. Meanwhile, the molded article is also suited for many other applications, including automobile parts and housing equipment parts. Potential Examples of such molded parts, which can be made of the PPS composition according to the present invention, include for example electrical and 34565-WO-PCT[2] - 24 - electronics applications, such as molded parts in 5G antenna radiator, notebook, tablet, insulated-gate bipolar transistor (IGBT), relay and capacitor and circuit breaker. Molded parts according to the invention can also be suitably employed in automotive applications, including for example E powertrain, Transport Management system (TMS), Battery system, fuel cell, Sensing and advanced driver assistance systems, such as housing for these. Molded parts according to the invention can further suitably employed in food, water and appliance applications, such as for example home appliance, water meter, sanitary ware, condensing boiler, water pipe, liner for water pipe, kitchen utensils. Molded parts according to the invention can also suitably be employed in general industry applications, such as for example valve, pump, printer, steam regulator, robotics, power storage. Molded parts according to the invention can suitably be employed in medical applications, such as surgical tool, oxygenator component, health care atomizer. Experiments Materials used PPS: Acid washed linear PPS with Melt Flow Rate 500g/10min (at 316 °C, 5 kg), (ex Zhejiang NHU Specialty Materials Co., Ltd). Glass fibres: E-glass fibres: chopped strand glass fiber, fiber length 3 mm, fiber diameter 10 µm (ex China Jushi Co., Ltd.). TPE-I: Epoxy-modified polyolefin copolymer (a copolymer of ethylene (E) and glycidyl methacrylate (GMA); GMA content: 8 mass%; Melt Flow Rate 5 g/10 min (at 190°C, 2.16 kg), melting point 104 °C) (ex SK Functional Polymer). TPE-II: non-modified polyolefin copolymer (a copolymer of ethylene (E) and octene-1 (OC); MFR 1.1 g/10 min at 190°C; Tg -50°C; (ex Borealis). TPE-III: Epoxy-modified polyolefin copolymer (a terpolymer of ethylene(E), methyl acrylate (MA) and glycidyl methacrylate (GMA); GMA content: 8 mass%; Melt Flow Rate 6 g/10 min (at 190°C, 2.16 kg), melting point 65 °C); (ex SK Functional Polymer). Metal carbonate: calcium carbonate (CaCO3); particle size distribution with median particle size (D50) 4 µm and D9810.2 µm ( ); (ex LianZhou DongNan New Materials CO., LTD). 34565-WO-PCT[2] - 25 - Mineral 1: Talc: Fineness 45 µm (test method GB/T15344 China standard) produced by Guangxi Longguang Talc Development Co., Ltd, LTD Mineral 2: CaSO4: Length 10-200 µm (90%) Diameter 1-4 µm (90%); (ex Jiangxi Fengzhu new materials technology CO., LTD). Additive 1: Aminopropyltriethoxysilane (Amino coupling agent) (ex Nanjing Shuguang Silane Chemical Co., Ltd). Additive 1: PPS based carbon black (CB) masterbatch (15 wt.% of CB in PPS) (ex Clariant Masterbatches SHG Ltd). PPS compositions of the Examples and the Comparative Experiments were made from the ingredients as listed in Table 1. The PPS compositions were prepared by uniformly mixing the PPS, the thermoplastics elastomer, and other additives as further required, with a tumbler, a Henschel mixer or the like, and melt kneading this in a Coperion STS35 twin screw extruder with a 35mm diameter with a cylinder temperature of 380° C. Further, among the components shown in Table 1 below, the glass fiber, calcium carbonate, talc and calcium sulfate were introduced into the extruder using a side feeder and melt kneaded. After extrusion, the materials produced were cooled and pelletized. The pellets of the various materials were dried at 110 °C overnight, and molded into test pieces using an injection molding machine at a cylinder temperature of 340 °C and at a mold temperature of 140 °C. Test sample for Tensile Strength (TS) and Tensile Elongation at Break (EAB) properties: ISO527 Type 1A specimen having a length of 150 mm, thickness of 4mm, and width of 20 mm Test sample for Flexural Strength (FS): cut from ISO527 Type 1A specimen, having a length of 80 mm, thickness of 4mm, and width of 10 mm Test sample for Notched Charpy Impact Strength (N-C): Cut from ISO527 Type 1A specimen, having length of 55 mm, thickness of 4 mm, and width of 10 mm, and having a notch, (0.25mm notched root radius, 2mm depth and 45 ° notch angle. 34565-WO-PCT[2] - 26 - Test sample for Un-notched Charpy Impact Strength (UN-C): cut from ISO527 Type 1A specimen, having length of 55 mm, thickness of 4 mm, and width of 10 mm Test sample for UL94: having a length of 125 mm, thickness of 0.8mm or 1.6mm, and width of 13 mm. Measurements and test methods Tensile Strength (TS), and Tensile Elongation at Break (EAB) Tensile properties were tested with the test method according to ISO 527. The measurements were performed on the test samples for Tensile Strength (TS) and Tensile Elongation at Break (EAB) properties. The testing temperature was 23°C and the testing speed was 5 mm/min. Flexural Strength Flexural properties were tested with the test method according to ISO 178. This test was be performed on a 64 mm support span. The measurements were performed on test samples for Flexural Strength. The testing temperature was 23°C. and the testing speed was 2 mm/min. Notched Charpy Impact Strength and Un-notched Charpy Impact Strength Notched Charpy properties were tested with the test method according to ISO 179-1. The measurements were performed on the test samples for Notched Charpy Impact Strength. The testing temperature was 23 °C. Un-notched Charpy properties were tested with the test method according to ISO 179-1. The measurements were performed on the test samples for Un-notched Charpy Impact Strength. The testing temperature was 23 °C. Flammability Flammability testing was done with the test method according to UL- 94 (20 mm Vertical Burning Test) using 0.8 mm or 1.6 mm thick test pieces, which were conditioned for either 48 hours at 23 °C and 50% relative humidity or 168 hours at 70 °C. Test results The test results show that the compositions of the Examples according to the Invention (E-1 E-6) and the Comparative Experiments (CE-A CE- 34565-WO-PCT[2] - 27 - G) are shown in Table 1. The test results show that the compositions of the Examples according to the Invention all have good mechanical properties in terms of high tensile strength, and flexural strength, as well as a high elongation at break of at least 2.0 %, a high un-notched impact resistance of at least 55 J/m, and a UL94 flammability rating of V0 at both 0.8 mm thickness and 1.6 mm thickness. The test results for the compositions of the Comparative Experiments either fail in the flammability test or have a lower elongation at break and/or a lower un-notched impact resistance.
34565-WO-PCT[2] - 28 -

Claims

34565-WO-PCT[2] - 29 - CLAIMS 1. PPS composition comprising a. Polyphenylene sulphide (PPS) in an amount in a range of 36 - 71.5 weight percentage (wt.%); b. Glass fibres in an amount in a range of 25 45 wt.%; c. Thermoplastic elastomer in an amount in a range of 2.5 6.5 wt.%; and d. Metal carbonate in an amount in a range of 1.0 8.0 wt.%; wherein the weight percentages (wt.%) are with respect to the total weight of the composition. 2. PPS composition according to claim 1, wherein the composition comprises less than 900 ppm of chlorine or bromine and less than 1500 ppm of total halogens, relative to the total weight of the composition. 3. PPS composition according to claim 1 or 2, wherein the thermoplastic elastomer is selected from the group consisting of polyolefin-based elastomers, styrene/butadiene/styrene block-copolymers, polyamide block- copolymers and polyester block-copolymers, and any combinations thereof. 4. PPS composition according to any one of claims 1-3, wherein the thermoplastic elastomer comprises at least a polyolefin-based elastomer, more preferably at least a functionalized polyolefin copolymer. 5. PPS composition according to any one of claims 1-4, wherein the thermoplastic elastomer comprises a functionalized polyolefin copolymer and a at least a non-functionalized polyolefin copolymer in a ratio by weight in the range of 20:80 - 90:10. 6. PPS composition according to any one of claims 1-5, wherein the composition comprises 3.0 6.0 wt.%, relative to the total weight of the composition, of a combination of a functionalized polyolefin copolymer and a non-functionalized polyolefin copolymer. 7. PPS composition according any one of claims 1-6, wherein the amount of thermoplastic elastomer is between 3.0 and 5.8 wt.%, relative to the total weight of the composition. 8. PPS composition according to any one of claims 1-7, wherein the metal carbonate is chosen from Group I metal carbonates represented by the formula M2CO3 and Group II metal carbonates represented by the formula MCO3, or a combination thereof. 34565-WO-PCT[2] - 30 - 9. PPS composition according to any one of claims 1-8, wherein the metal carbonate comprises calcium carbonate or magnesium carbonate, or a combination thereof, the metal carbonate preferably comprises calcium carbonate. 10. PPS composition according to any one of claims 1-9, wherein at most 10% of the number of particles have a size larger than 40 micrometer, preferably at most 5% of the number of particles have a size larger than 20 micrometer. 11. PPS composition according any one of the preceding claims, wherein the amount of metal carbonate is in the range of 3.0 6.0 wt.%, relative to the total weight of the composition. 12. PPS composition according to any one of the preceding claims, wherein the composition consists of a. 36 71.5 wt.% of polyphenylene sulphide (PPS); b. 25 45 wt.% of glass fibres; c. 2.5 6.5 wt.% of a thermoplastic elastomer; d. 1.0 8.0 wt.% of a metal carbonate; and e. 0 5.0 wt.% of one or more further additives; wherein the weight percentages (wt.%) are relative to the total weight of the composition, and the sum of the listed amounts is 100 wt.%. 13. PPS composition according to claim 12, wherein the further additive comprises a silane-based coupling agent compound selected from the group consisting of methacryloxy silane compounds, ureido silane compounds, epoxy silane compounds and amino silane compounds; preferably an amino silane. 14. Process for preparing a PPS composition comprising a melt-mixing step of melt-mixing a. 36 71.5 wt.% of polyphenylene sulphide (PPS); b. 25 45 wt.% of glass fibres; c. 2.5 6.5 wt.% of a thermoplastic elastomer; d. 1.0 8.0 wt.% of a metal carbonate; and e. 0 5.0 wt.% of one or more further additives; wherein the weight percentages (wt.%) are relative to the total weight of the composition, and the sum of the listed amounts is 100 wt.%. 34565-WO-PCT[2] - 31 - 15. Process for the production of a molded part, the process comprises a melt- processing step and wherein the molded part is made of a PPS composition comprising: a. 36 71.5 wt.% of polyphenylene sulphide (PPS); b. 25 45 wt.% of glass fibres; c. 2.5 6.5 wt.% of a thermoplastic elastomer; d. 1.0 8.0 wt.% of a metal carbonate; and e. 0 5.0 wt.% of one or more further additives; wherein the weight percentages (wt.%) are relative to the total weight of the composition, and the sum of the weight percentages is 100 wt.%. 16. Molded part, comprising the PPS composition as defined in any of the preceding claims.
EP23832738.1A 2022-12-23 2023-12-14 Pps composition, process for preparation, process for producing an article, and article made of the composition Pending EP4638601A1 (en)

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