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Vinyl Functionalized PPE Resin for Varnish Applications

IP.com Disclosure Number: IPCOM000020752D
Publication Date: 2003-Dec-12

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. 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. Replacing the hydroxyl group on SA120 with a reactive methacrylate forms the developmental product PPO® MX5587 resin. PPO® MX5587 resin can be used as the building block for varnishes, potting compounds, or laminate applications. Thermosettable Noryl® resin is a hybrid material that bridges the performance gap between thermoplastics and thermosets. Depending on the filler type and loading, Thermosettable Noryl® resin can potentially be used in applications such as fuel cell conductive plates, automotive-electrical applications, super-abrasive grinding wheels, aerospace and high performance composites, automotive body panels, truck boxes, electrical insulation, microchip encapsulants, printed circuit boards, sheet, syntactic foam, and other foam structures, or neat resin applications such as electrical grade varnishes including all different types of processing, such as dip and bake, vacuum pressure impregnation, roll through, or total encapsulation. The potential applications are not limited to electrical grade varnishes, other potential uses include resin applications requiring filling of large areas and voids for environmental protection. The data show that certain compositions containing PPO® MX5587 resin may have improved fracture toughness, higher heat resistance, better dielectric properties, and lower moisture uptake compared to unsaturated polyester resins and varnishes as well as vinyl ester resins and varnishes. In addition to PPO® MX5587 resin which has an intrinsic viscosity (IV) of 0.12 dl/g, other vinyl capped PPE resins such as 0.15 IV and 0.25 IV can be tailored to meet specific requirements. Key Words: polyphenylene oxide, PPO, polyphenylene ether, PPE, Thermosettable Noryl resin, TSN, methacrylate endgroup, vinyl capped, heat resistance, chemical resistance, toughness, laminate, varnish, foam

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Slide 1 of 10

NORYL® ETX Resin Applications

General Electric Company


Slide 2 of 10

Noryl® ETX Technology

Polyphenylene ether - Al Hay 1956

PPE Features

  Amorphous polymer

  High Tg (205-210°C)

  Outstanding electrical properties

  Hydrolytic stability

  No hydrolizable bonds

  Very low moisture adsorption

  Inherent flame resistance (non-halogen FR products)

  Blends and Alloys (polystyrene, polyamide, polypropylene, etc.)

PPE

Where R = CH3

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Slide 3 of 10

Noryl® ETX Resin

   

PPO ® resin side chains

 

Cross-linked matrix

           
         
     
 

Thermoplastics

Cross-linked Thermoset

Noryl ® ETX Resin

Vinyl functionalized PPO ® resin

+ vinyl monomer + Cross-linker

Key variables:

Ratio of PPO® Resin:Vinyl monomer: Cross-linker

Structure of cross-linker


Slide 4 of 10

CHEMISTRY

NORYL® ETX Resin Building Blocks

   

OH

       
   
   
     
   

Crosslinked matrix

PPO ® resin chains

Vinyl

Monomer

Such as Styrene

Regular PPO ® resin

Hydroxyl-Capped

New Chemistry

O

Noryl ® ETX

O

Other additives,

Such as crosslinker*,

free radical initiator**, etc.

PPO-MAA

Vinyl-Capped PPO® Resin

* such as listed in Sartomer catalogue (http://www.sartomer.com/)

** such as listed in “Handbook of free radical initiators”, by E. T. Densisov, T. G. Denisova, and T. S. Pokidova, Wiley-Interscience (2003)

 
New Chemistry - Vinyl Functionalized PPO ® resin creates new Thermoset resin

 
Hybrid Material – Thermoset Matrix with Thermoplastic character in its back-bone

 
Amount of Thermoplastic & Cross-linked nature can be dialed-in

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Slide 5 of 10

PROPERTIES OF UNFILLED RESINS

EFFECT OF CROSS-LINKER TYPE*

  CROSS-LINKER K1c,

Mpa-m 1/2 Flex

Strength, PSI Flex

Modulus, PSI Tg

(DMA), deg C

SR351 TRIMETHYLOLPROPANE TRIACRYLATE 1.10 5698 394287 145

SR350 TRIMETHYLOLPROPANE TRIMETHACRYLATE 1.20 12574 390244 140

SR454 ETHOXYLATED (3) TRIMETHYLOLPROPANE TRIACRYLATE 1.20 15321 378733 103

SR499 ETHOXYLATED (6) TRIMETHYLOLPROPANE TRIACRYLATE 1.97 13471 370572 90

SR502 ETHOXYLATED (9) TRIMETHYLOLPROPANE TRIACRYLATE 2.45 11226 312566 76

CD406 CYCLOHEXANE DIMETHANOL DIACRYLATE 1.04 11725 376060 80

SR508 DIPROPYLENE GLYCOL DIACRYLATE 1.17 14088 377793 105

SR248 NEOPENTYL GLYCOL DIMETHACRYLATE 1.40 12100 432098 140

RESINS = 28% PPO ® Resin , 52% Styrene, and 20% CROSS-LINKER

Can vary properties with type of Cross-linker

Flexible x-linkers:

increased toughness

lower Tg, strength and modulus

* For illustration purpose only


Slide 6 of 10

Effect of Crosslinker Structure*

Crosslinkers Studied Gave High Fracture Toughnesses (> 1.0 MPa-m1/2)

Small Effect of Acrylate Structure on TSN Fracture Toughness/Tg

Polar Acrylates Give Moderate Dk/Excellent Df

* For illustration purpose only

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Slide 7 of 10

UNFILLED RESIN COMPARISON*

    Strength Toughness Thermal Dielectric Moisture

Neat Resins Flexural

Strength (Kpsi) K1c

(Mpa-m 1/2 ) Tg (°C) Dk Df H2O Abs (%)

Noryl ® ETX Resins 5-15 1.1-1.3 130-150 2.8-3.9 0.0...