Polyester compositions, method of manufacture, and uses thereof

A composition consisting essentially of, based on the total weight of the composition:

• from 35 to 65 wt. % of a modified polybutylene terephthalate random copolymer that (1) is derived from polyethylene terephthalate component selected from the group consisting of polyethylene terephthalate and polyethylene terephthalate copolymers and (2) that has at least one residue derived from the polyethylene terephthalate component;
• from 5 to 25 wt. % of
• a flame retardant phosphinate of the formula (Ia)
• [(R1)(R2)(PO)—O]−3Al3+ (Ia),
• a flame retardant diphosphinate of the formula (IIa)
• [(O—POR1)(R3)(POR2—O)]2−3Al3+2 (IIa), and/or
• a flame retardant polymer derived from formula (I) or (II),
• wherein R1 and R2 are identical or different and are H, C1-C6-alkyl, linear or branched, and/or aryl;
• R3 is C1-C10, alkylene, linear or branched, C6-C10-arylene, -alkylarylene or -arylalkylene;
• from 1 to 25 wt. % of melamine polyphosphate and/or melamine cyanurate;
• from 0.1 to 25 wt. % of an aromatic polyetherimide;
• from 15 to 45 wt. % of a reinforcing filler;
• and
• from 0 to 3 wt. % of a chlorinated and/or brominated organic flame retardant compound,
• wherein the at least one residue derived from the polyethylene terephthalate component includes a mixture of ethylene glycol groups, diethylene glycol groups, and isophthalic acid groups;
• and
• wherein a molded sample comprising the composition has a tensile strength at yield from 90 to 120 MPa measured in accordance with ISO 527, and an unnotched Izod impact strength from to 25 to 50 kJ/m2 measured at 23° C. in accordance with ISO 180, and a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0.

A composition consisting essentially of, based on the total weight of the composition:

• from 40 to 65 wt. % of a modified polybutylene terephthalate random copolymer that (1) is derived from polyethylene terephthalate component selected from the group consisting of polyethylene terephthalate and polyethylene terephthalate copolymers, (2) that has at least one residue derived from the polyethylene terephthalate component, and (3) that has a weight average molecular weight of 45,000 a.m.u. or greater, as determined by gel permeation chromatography with a polystyrene standard;
• from 7 to 20 wt. % of
• a flame retardant phosphinate of the formula (Ia)
• [(R1)(R2)(PO)—O]−3Al3+ (Ia),
• a flame retardant diphosphinate of the formula (IIa)
• [(O—POR1)(R3)(POR2—O)]2−3Al3+2 (IIa), and/or
• a flame retardant polymer comprising formula (Ia) or (IIa),
• wherein R1 and R2 are identical or different and are H, C1-C6-alkyl, linear or branched, and/or aryl;
• R3 is C1-C10, alkylene, linear or branched, C6-C10-arylene, -alkylarylene or -arylalkylene;
• from 2 to 8 wt. % of melamine polyphosphate and/or melamine cyanurate;
• from 2 to 8 wt. % of an aromatic polyetherimide;
• and
• from 20 to 35 wt. % of a reinforcing filler;
• wherein the at least one residue derived from the polyethylene terephthalate component comprises a mixture of ethylene glycol groups and diethylene glycol groups.

A composition comprising:

• (a) from 20 to 80 wt. % of a polyester component comprising a modified polybutylene terephthalate random copolymer that (1) is derived from polyethylene terephthalate component selected from the group consisting of polyethylene terephthalate and polyethylene terephthalate copolymers and (2) that has at least one residue derived from the polyethylene terephthalate component containing mixtures of ethylene glycol groups, diethylene glycol groups, and isophthalic acid groups;
• (b) from 5 to 35 wt. % of
• a flame retardant phosphinate of the formula (I)
• [(R1)(R2)(PO)—O]−mMm+ (I)
• a flame retardant diphosphinate of the formula (II)
• [(O—POR1)(R3)(POR2—O)]2−nMxm+ (II), and/or
• a flame retardant polymer derived from the flame retardant phosphinate of the formula (I) or the flame retardant diphosphinate of the formula (II),
• wherein R1 and R2 are identical or different and are H, C1-C6-alkyl, linear or branched, and/or aryl;
• R3 is C1-C10, alkylene, linear or branched, C6-C10-arylene, -alkylarylene or -arylalkylene;
• M is an alkaline earth metal, alkali metal, Al, Ti, Zn, Fe, boron;
• m is 1, 2, 3 or 4;
• n is 1, 2, or 3;
• and x is 1 or 2;
• (c) from 1 to 25 wt. % of a melamine polyphosphate, melamine cyanurate, melamine pyrophosphate, and/or melamine phosphate;
• and
• (d) from more than 0 to 25 wt. % of a polyetherimide;
• (e) a quencher component selected from the group consisting of from 0.1 to 1 wt % of poly(methyl hydrogensiloxane), from 0.1 to 1 wt % 3-aminopropyl trialkoxysilane, mixtures of ZnS and ZnO, wherein the ZnO is less than 50% of the mixture, and combinations thereof;
• and optionally an additive component selected from the group consisting of an antioxidant, a lubricant, a thermal stabilizer, an ultraviolet light absorbing additive, a plasticizer, an antidripping agent, a mold release agent, an antistatic agent, a dye, a pigment, a laser marking additive, a radiation stabilizer, and a combination thereof
• wherein an article molded or extruded from the composition has a heat deflection temperature that is equal to or greater than 190 C and an unnotched Izod impact strength from to 25 to 50 kJ/m2 measured at 23° C. in accordance with ISO 180, and a 0.8 mm thick molded sample comprising the composition has a UL-94 flammability rating of V0;
• wherein components (a), (b), (c), (d), (e) and the optionally additive component have a combined total weight of 100 wt. %.