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Property Improvements of Unsaturated Polyester Resins with Low Molecular Weight PPOÒ Resin

IP.com Disclosure Number: IPCOM000005684D
Publication Date: 2001-Oct-25

Publishing Venue

The IP.com Prior Art Database

Abstract

PPO SA120 resin is a new low molecular weight (Mn »2500) polyphenylene-ether (PPE) resin recently commercialized by GE Plastics as a polymer additive. In addition to having the well-known properties inherent to PPE, this new resin has an excellent thermal performance--glass transition temperature (Tg) of 165°C combined with a characteristic feature of improved processability. PPO 855A resin is a new functionalized PPE resin designed for UPR systems. The functionalized end groups lead to better reactivity of PPE with the resin system. The low molecular weight of the new PPE resin allows PPE to be more easily processed in unsaturated polyester resin (UPR) and vinyl ester resin (VER) systems. By functionalizing the end groups the traditional OH end groups of PPE, which inhibit free radical reaction, are replaced. The functionalization is done with reactive or non-reactive end groups. PPO 855A is a salicylate functionalized PPE for non-reactive capping. PPO MX5587 (developmental grade) is an acrylic functionalized PPE for reactive capping. Reported herein is an evaluation of PPOÒ 855A and PPO MX5587 in UPR systems. PPE can be dissolved directly into styrene then added to the resin system. The addition of either PPE grade reduces shrinkage better than other low profile additives (LPA) such as polyvinyl acetate. Other properties such as Tg, heat distortion temperature, water absorption, and electrical properties are also improved with PPE, while the curing kinetics are not negatively affected by PPE. Key Words: polyphenylene oxide, PPO, polyphenylene ether, PPE, polyoxyphenylene functionalized, reactive end groups, non-reactive end groups, UPR, unsaturated polyester resin, VER, vinyl ester resin, BMC, bulk molding compound, SMC, sheet molding compound, pultrusion, RTM, resin transfer molding, injection molding, LPA, low profile additive, SCA, shrinkage control agent

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Page 1 of 22

g GE Plastics

Introduction

®

© 2001. General Electrical Company

PPO ® is registered Trademark(s) of General Electric Company

[This page contains 1 picture or other non-text object]

Page 2 of 22

g GE Plastics PPO

® resin History

• Polyphenylene Ether (PPO ® resin) Discovered By GE in 1956 (A. Hay, GE Corporate R&D, Schenectady, NY)

• Commercial Process Defined for 2,6-Xylenol in 1960
• Pilot scale PPO
® resin Production in 1964
• NORYL
® resin (PPO® resin/HIPS) Commercialized by mid-1960's
• NORYL GTX
® resin (PPO® resin/Nylon) Introduced in the 1980's

PPO ® resin: Large Part of GE's Past…And Our Future

Page 3 of 22

g GE Plastics

Polymerization

H

O

OH

OH

n

R

R

O

OH

O

Cu/Amine

O2

O

O

n

H

O

n

H

O

H

n

R=H. Alkyl

O

n

H

PPE resin is prepared by oxidative polymerization of 2,6-dimethylphenol using a copper catalyst. This reaction yields a low molecular weight polymer and tetramethyldiphenoquinone (TMDQ). i The TMDQ formed during polymerization is incorporated into the polymer through redistribution, ii producing polymer chains of listed structures

i Hay, A.S. Blanchard, H.S., Endres, G.F. Eustance, J.W. J. Am. Chem. Soc. 81, 6335 (1959).

ii White, D. M. J. Appld. Poly. Sci. Poly. Chem. Ed. 19, 1008 (1979); U.S. Patetn no. 4,140,675 (Feb 20, 1979), D. M. White (to General Electric Co.)

Page 4 of 22

g GE Plastics

Properties

How Does PPO ® resin ?

• Heat (Tg)
• Electrical Properties (Dk, Df)
• Toughness
• Eco-FR
• Low Moisture Absorption
• Dimensional Stability
• Shrinkage Control
• Resistance To Acids & Bases

Polymer System Turbocharger

Page 5 of 22

g GE Plastics

Applications

Your Polymer System

+

Adhesives & Sealants

Electrical/Electronics

Composites

Coatings

Others

Thermosets
Epoxies
Unsaturated Polyesters
Cyanate Esters
Others
Elastomers
SBC
SBR
Others
Thermoplastics

Turbocharge Your Formulations & Grow Your Business

Page 6 of 22

g GE Plastics

The Grades

Standard PPO ® resin Grades

1) PPO ®803 / PPO ® 640, IV = 0.40 dl/g
2) PPO
®800 / PPO ® 646, IV = 0.46 dl/g
3) PPO
®805, IV = 0.57 dl/g
4) Concentrates: 6390C & 6370C

Specialty PPO ® resin Grades

1) PPO ® SA120, IV = 0.12 dl/g, OH = 425 m mol/g (formerly PPO ®857)

2) PPO ® SA123, IV = 0.12 dl/g, Acid grafted low IV
3) PPO
® SA125, IV = 0.12 dl/g, Capped with Reactive unsaturated group
4) PPO ® SA407, IV = 0.40 dl/g, Capped (855AResin)
5) PPO
®6130, IV = 1.50 dl/g, Gas sep. grade, ultra-high IV

Non-bold = developmental grades

Page 7 of 22

Custom Design

g GE Plastics

Custom design Reactivity by controlling functionality

Processability by controlling molecular weight

Goal:

No inhibition to Free radical reaction / curing
Incorporate & build-in PPO ® in polymer network.

No phenolic end group & low molecular weight & reactive or non-reactive end groups

OH

O n

Inhibition No inhibition

O-X

O n

Salicylate functionalized PPO ® for non-reactive capping (PPO ® 855A)
Acrylic functionalized PPO ® for reactive capping (PPO ® MX5587 developmental grade)

Salicyla...