# Patent

## Title
Thermoplastic polymer for electrically conductive thermoforming applications

## Abstract

This invention relates to a thermoplastic polymer composition that exhibits excellent characteristics for being thermoformed into a wide variety of packaging trays for electronics, including the disk drive and semiconductor industries. More specifically, these trays are applicable as packaging material for head suspension assembly and offer conductivities in the range of antistatic to electrostatic dissipation (ESD). For instance, the thermoplastic polymer composition of this invention offers improved stiffness, improved chemical resistance, the capable of enduring more washing cycles, the capability of being dried at higher temperatures, improved cleanliness, and better electrical conductivity that conventional PETG/IDP polymer blends. The thermoplastic polymer composition of this invention is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.

## Background
FIELD OF THE INVENTION
This invention relates to a thermoplastic polymer which can be thermoformed into electrically conductive packaging for the electronics industry. This thermoplastic polymer can be beneficially utilized in manufacturing trays for supporting disk drive head suspension assemblies during storage, transportation, cleaning and manufacturing procedures.
BACKGROUND OF THE INVENTION
In many industries, component parts used in the assembly of a larger item of equipment are often shipped to an assembler in either disposable or recyclable packages. Typically, the manufacturer removes the component from the shipping package, and places the component into a processing fixture. The processing fixture holds the component sufficiently rigid such that certain processes can be performed on the component. Removal of a component from its shipping tray and placement into the processing fixture can be done either by automation or manually.
While the foregoing describes a common method of assembling component parts into a larger whole, it also describes a process infused with complexity and cost. If the components are removed with automation, the capital cost of such equipment and related overhead adds cost to the manufacturer. If the components are removed manually, the labor rate of the operators performing this act also increases the manufacturer's cost. Further, in many cases, the processing fixtures employed by manufacturers are complex and costly. Finally, where the components are fragile or otherwise easily damaged, the removal of the component from its shipping package and its installation into a processing fixture, whether by hand or through some automated procedure, may result in costly component damage from the handling of the component
As an illustration of the foregoing methods and processes and the problems associated therewith, the hard disk drive industry can be considered. A hard disk drive is the device most predominantly used for long term memory/data storage in modern computer systems. In overview, a hard disk drive comprises a disk that is rotated at high speeds. The disk has a magnetic coating or read/write media that can be selectively magnetized with the application of a magnetic field thereto. A “read/write” device, commonly called a head, is attached to and held closely adjacent the disk by a head suspension assembly and is moved radially relative to the rotating disk, that is, from the edge of the disk toward the center and back. Electric current is provided to the head which creates and applies a magnetic field to the disk as the head moves relative thereto. Selective areas of the disk are preferentially magnetized as the magnetic field is applied to the disk. Each magnetized area consists of a north and south pole selectively oriented in one of two preferred directions. Magnetized areas having a north pole pointing in one of the two direction are designated as a “0” and in the other direction as a “1 ” In this way the binary language of computers consisting of zeroes and ones is assembled on the magnetized disk coating and data and programs, which comprise zeroes and ones in binary computer language, are stored on the hard disk.
Continuing with the example of the disk drive industry, head suspension assemblies are shipped in disposable vacuum-formed trays to manufacturers who may attach the read/write head thereto. The manufacturers remove the head suspension assembly from its shipping tray and place it into an intricate processing fixture, referred to as a “head bond fixture.” Typically, head bond fixtures are precise, machined metal fixtures with several moving parts. Often times, these fixtures include a small clamping mechanism to hold the suspension assembly sufficiently rigid during the assembly process. The surface of the fixture which mates with the suspension assembly is ground to complex geometries with very tight tolerances, thus making them very costly. Once placed within the head bond fixture, the suspension assembly is held in such a manner that a read/write head can be bonded to it.
As in any industry, manufacturing costs in the hard disk drive industry are carefully monitored. The hard disk provides large amounts of storage capability at relatively low cost. As the technology continually matures, the storage density per unit of cost, that is, the quantity of data stored per dollar, is continuously increasing, as is the reliability of the hard disk and its related components, (collectively called the hard disk drive, hard drive, or disk drive) and the rate at which data can be transferred to and from the disk. That is, advancing hard disk technology is resulting in the storage of increasing amounts of information at decreasing unit costs. Yet, in spite of the rapid advance in storage technology, the technology continues to face cost pressures as competition in the marketplace intensifies and computer programs grow in size. It would be helpful if the cost pressures arising out of damage that occurs during the assembly process could be reduced as well as the cost pressures that result from labor or inflexible tooling intensive processes.
Head suspension assemblies are extremely fragile and susceptible to damage from handling such as that occurring during the assembly process. That is, the act of removing a head suspension assembly from its packaging and installing it in a processing fixture can result in the destruction of the assembly or damage it so as to degrade seriously the suspension's later operational performance.
One source of possible damage to the components stems from electrostatic discharge (ESD) or electrical overstress (EOS), collectively referred to as ESD/EOS. ESD/EOS usually results from touching an object and causing a build-up of static charges. Prior to the time that the head suspension assembly is installed into a disk drive, the electrical interconnect is electrically connected to the read and write elements, but is not connected to the drive electronics. As a result, the individual conductors that make up the electrical interconnect, can easily be charged by stray voltages, thereby creating a voltage potential across the sensitive magnetoresistive or giant magnetoresistive read elements of the read/write head, which when discharged results in damaging current transients through the read element.
The components used in hard disk drives are small and continually decreasing in size. Consequently, any tolerance for ESD/EOS damage of the components during the assembly process is also continuously decreasing while their susceptibility to damage during assembly is increasing. The present methods of assembly, however, are the source for the creation of much static potential charge, whether through direct handling of the component parts or because of the human assemblers doing some normal activity such as shuffling their feet or wiping their brow. Minimizing the handling of the head suspension assembly is thus desirable, yet present packaging, transportation and assembly methods result in the need for an undesirable amount of such handling.
The small size of the components and their continually decreasing size also reduces any tolerance for misalignment of the components during the assembly process while increasing their susceptibility to damage during assembly. Current disk drive assembly includes expensive, labor intensive processes, particularly the assembly of the flex circuit to the suspension assembly. The labor intensive nature of the assembly process has several consequences. First, the labor increases the final cost of the assembled suspension. Second, because of the heavy use of labor in the assembly, there is a meaningful quantity of handling of the components by the assembler, which increases the likelihood of damage to the components. Third, the assemblers are limited in both the precision and speed with which the flex circuits can be assembled to the suspensions. Fourth, even though human assemblers are used, the assembly process is quite tooling intensive. Fifth, as the part geometries change as the technology advances, the costs also increase because of the need for new tooling in the assembly of the new parts; that is, the tooling used is either not adaptable or not readily adaptable to new part geometries.
Additional costs that are not included in calculation of the cost of the use of human assemblers are those of the consumer whose hard drive fails, perhaps due to damage to a component by a human assembler. Though data backups are always advised, such advice is often unheeded. When a hard drive fails the consumer may lose valuable data that is either not easily replaced or is replaced only at some cost in terms of time and effort, if not actual cash outlays.
Many of the foregoing deficiencies in the employment of human assemblers could be reduced or eliminated with a precision automated assembly apparatus and method for attaching flex circuits to suspensions. Automated assembly machines and methods should result in lower costs, reduced component handling and possible damage, and have greater flexibility to accommodate variations in component types, geometries and improved placement tolerances. Simple automation of the actual assembly of the flex circuit to the suspension will not, however, eliminate the problems associated with removing the components from their shipping trays and placing them in an assembly apparatus.
For the reasons delineated above, there was a need for an inexpensive packaging tray that can also be utilized as a processing fixture. This approach has several advantages over the processes and apparatus described above. First, because the components need not be removed from the shipping tray during subsequent manufacturing processes, the likelihood of damage resulting from handling is significantly reduced. Second, the costs associated with the removal of the component from the shipping package are eliminated. Finally, this approach eliminates the need for costly processing fixtures. Disk drive head suspension assembly trays that can be used in storage, transportation, cleaning and manufacturing procedures are described in U.S. Pat. No. 7,191,512.
U.S. Pat. No. 7,191,512 more specifically describes a tray system for holding and positioning head suspensions as components, the tray system comprising: a first tray comprising a first side having at least one component receptacle and an opposite second side having at least one component receptacle, wherein at least one of the component receptacles of the first side of the first tray comprises a base plate seat positioned adjacent a first load beam seat, and at least one of the component receptacles of the second side of the first tray comprises a base plate collar seat adjacent a second load beam seat; and a second tray engageable with the first tray, the second tray comprising a first side having at least one component receptacle and an opposite second side having at least one component receptacle, wherein at least one of the component receptacles of the first side of the second tray comprises a base plate seat positioned adjacent a first load beam seat, and at least one of the component receptacles of the second side of the second tray comprises a base plate collar seat adjacent a second load beam seat, wherein the second side of the first tray is adjacent the first side of the second tray so that the at least one component receptacle of the first side of the second tray is substantially aligned with the at least one component receptacle of the second side of the first tray for cooperatively restraining the motion of at least one component, of the components, positioned therein.
U.S. Pat. No. 7,360,653 describes a tray for supporting a plurality of disk drive suspension assemblies that either have a first configuration or a second configuration that is generally a mirror image of the first configuration, each disk drive suspension assembly having a load beam with a proximal mounting region having an aperture and a tail member extending proximally from the mounting region, the tray comprising: a frame; a first member extending across the frame and having a plurality of first support features, each first support feature, adapted to support the mounting region of a suspension assembly of the first configuration and of the second configuration; and a second member extending across the frame and having a plurality of tail support features, each adapted to support a portion of a tail member proximal to the mounting region and constrain lateral movement of the supported portion of the tail member, wherein each tail support feature is positioned relative to a respective first support feature so as to support and laterally contain the portion of the tail member of a disk drive suspension assembly of the first configuration or the portion of the tail member of a disk drive suspension assembly of the second configuration.
U.S. Pat. No. 7,360,653 also describes a tray for supporting a plurality of disk drive suspension assemblies each having a flexible load beam with a proximal mounting region, wherein the load beam in a neutral position extends from the proximal mounting region and wherein deflection of the load beam from the neutral position beyond a plastic deformation position causes plastic deformation of the load beam, the tray comprising: a frame; a first member extending across the frame and adapted to support the proximal mounting regions of the plurality of suspension assemblies; and a second member extending across the frame, the second member being spaced apart from the load beams in their neutral position and for contacting the load beams before the load beams are in their plastic deformation position.
The disk drive head suspension assembly trays of the prior art have typically been made by injection molding, vacuum forming, or thermoforming a blend of polyethylene terephthalate glycol (PETG) with an inherently dissipative polymer (IDP) based on a polyamide or a copolyester-amide. However, polymer blends of this type are far from optimal as a material for use in automated manufacturing of disk drive head suspension assembly trays. For instance, it would be desirable for the thermoplastic polymer used in making such head suspension assembly trays to offer improved stiffness, good dimensional tolerances, improved chemical resistance, to be capable of enduring more washing cycles, to be capable of being dried at higher temperatures, to display improved cleanliness, and to exhibit higher electrical conductivity.
SUMMARY OF THE INVENTION
This invention relates to a thermoplastic polymer composition that exhibits excellent characteristics for being thermoformed into disk drive head suspension assembly trays. More specifically, these trays are applicable as packaging material for head suspension assembly and offer conductivities in the range of antistatic to electrostatic dissipation (ESD). For instance, the thermoplastic polymer composition of this invention offers improved stiffness, good dimensional tolerances, improved chemical resistance, the capability of enduring more washing cycles, the capability of being dried at higher temperatures, improved cleanliness, and better electrical conductivity that conventional PETG/IDP polymer blends. Additionally, the thermoplastic polymer compositions of this invention are inherently black in color which is critical for laser-driven automated processes.
The thermoplastic polymer composition of this invention is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
The present invention also relates to a disk drive head suspension assembly tray which is comprised of an exterior frame having substantially perpendicularly adjacent sides, frame sides having essentially planar top and bottom surfaces, at least two feet, at least two foot seats, at least one support rib, and a repository that is adapted to seat and retain a disk drive head suspension, wherein the disk drive head suspension assembly tray is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
The subject invention also specifically reveals a tray system for holding and positioning head suspensions as components, the tray system comprising: a first tray comprising a first side having at least one component receptacle and an opposite second side having at least one component receptacle, wherein at least one of the component receptacles of the first side of the first tray comprises a base plate seat positioned adjacent a first load beam seat, and at least one of the component receptacles of the second side of the first tray comprises a base plate collar seat adjacent a second load beam seat; and a second tray engageable with the first tray, the second tray comprising a first side having at least one component receptacle and an opposite second side having at least one component receptacle, wherein at least one of the component receptacles of the first side of the second tray comprises a base plate seat positioned adjacent a first load beam seat, and at least one of the component receptacles of the second side of the second tray comprises a base plate collar seat adjacent a second load beam seat, wherein the second side of the first tray is adjacent the first side of the second tray so that the at least one component receptacle of the first side of the second tray is substantially aligned with the at least one component receptacle of the second side of the first tray for cooperatively restraining the motion of at least one component, of the components, positioned therein; wherein the first tray and/or the second tray are comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
The present invention also reveals a tray for supporting a plurality of disk drive suspension assemblies each having a flexible load beam with a proximal mounting region, wherein the load beam in a neutral position extends from the proximal mounting region and wherein deflection of the load beam from the neutral position beyond a plastic deformation position causes plastic deformation of the load beam, the tray comprising: a frame; a first member extending across the frame and adapted to support the proximal mounting regions of the plurality of suspension assemblies; and a second member extending across the frame, the second member being spaced apart from the load beams in their neutral position and for contacting the load beams before the load beams are in their plastic deformation position; wherein the tray is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
The subject invention further reveals a tray for supporting a plurality of disk drive suspension assemblies each having a flexible load beam with a proximal mounting region, wherein the load beam in a neutral position extends from the proximal mounting region and wherein deflection of the load beam from the neutral position beyond a plastic deformation position causes plastic deformation of the load beam, the tray comprising: a frame; a first member extending across the frame and adapted to support the proximal mounting regions of the plurality of suspension assemblies; and a second member extending across the frame, the second member being spaced apart from the load beams in their neutral position and for contacting the load beams before the load beams are in their plastic deformation position; wherein the tray is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.
The present invention also discloses a process for making a thermoplastic polymer composition which comprises (1) mixing a polyethylene terephthalate glycol copolymer and carbon nanotubes in a first mixing step to produce a PETG/carbon nanotube premix, and (2) mixing additional polyethylene terephthalate glycol copolymer, a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, a functionalized rubbery polymer, an acrylic based core-shell polymer, and a lubricant selected from the group consisting of high density polyethylene and polyester wax throughout the PRTG/carbon nanotube premix made in step (1), wherein from 25 weight percent to 70 weight percent of the total constituents of the thermoplastic polymer composition are added in step (1) to make the premix.


DETAILED DESCRIPTION OF THE INVENTION
The polyethylene terephthalate glycol copolymer (PETG) used in the thermoplastic polymer compositions of this invention has repeat units that are derived from terephthalic acid, ethylene glycol, and an additional glycol selected from the group consisting of 1,4-cyclohexanedimethanol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 2,2-dimethyl-1,3-propanediol, 1,6-hexanediol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,2-cyclohexanedimethanol, and 1,3-cyclohexanedimethanol. Ethylene glycol will typically constitute from about 60% to 90% of the glycol component used in synthesizing the PETG and the additional glycol will accordingly make up the remaining 10% to 40% of the glycol component. Ethylene glycol will more typically constitute from about 70% to 80% of the glycol component used in synthesizing the PETG and the additional glycol will accordingly make up the remaining 20% to 30% of the glycol component. It is typically preferred to utilize 1,4-cyclohexanedimethanol as the additional glycol. Such a PETG would accordingly be comprised of polymer chains that are derived from terephthalic acid, ethylene glycol, and 1,4-cyclohexanedimethanol.
The PETG used in the practice of this invention can also be made by polymerizing a second dicarboxylic acid in addition to terephthalic acid therein. Such amorphous PETG will accordingly have repeat units that are derived from terephthalic acid, ethylene glycol, and the additional dicarboxylic acid. The repeat units that are derived from the additional dicarboxylic acid will act to inhibit crystallization in such polymers. The additional dicarboxylic acids that can be used for this purpose will typically contain from 8 to 16 carbon atoms. Some representative examples of aromatic dicarboxylic acids that can be used include isophthalic acid, orthophthalic acid, 1,8-naphthalenedicarboxylic acid, 1,7-naphthalenedicarboxylic acid, 1,6-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 1,7-anthracenedicarboxylic acid, 2,6-anthracenedicarboxylic acid, 2,7-anthracenedicarboxylic acid, 2,6-phenalenedicarboxylic acid, 1,6-phenalenedicarboxylic acid, 1,7-phenalenedicarboxylic acid, 2,8-naphthacenedicarboxylic acid, 2,9-naphthacenedicarboxylic acid, 1,7-naphthacenedicarboxylic acid, 1,10-naphthacenedicarboxylic acid, 2,7-pyrenedicarboxylic acid, 2,6-pyrenedicarboxylic acid, and 2,8-pyrenedicarboxylic acid. Isophthalic acid and 2,6-naphthalenedicarboxylic acid are preferred dicarboxylic acids for utilization in the acid component of such amorphous PETG polyesters in conjunction with the terephthalic acid. It should also be understood that the PETG can be modified with both a glycol in addition to ethylene glycol and with a diacid in addition to terephthalic acid.
The PETG used in the practice of this invention is thermoformable and typically has a melt viscosity which is within the range of 0.8 to 10 grams per 10 minutes. The PETG used in the practice of this invention preferably has a melt viscosity which is within the range of 0.9 to 5 grams per 10 minutes, and most preferably has a melt viscosity which is within the range of 1 to 3 grams per 10 minutes.
The carbon nanotubes used in making the thermoplastic polymer compositions of this invention normally have a diameter which is within the range of 5 to 20 nanometers and have a length which is within the range of 1 to 5 microns. The carbon nanotubes used in making the thermoplastic polymer compositions of this invention more typically have a diameter which is within the range of 7 to 15 nanometers and have a length which is within the range of 1 to 3 microns. The carbon nanotubes used in making the thermoplastic polymer compositions of this invention preferably have a diameter which is within the range of 8 to 13 nanometers and have a length which is within the range of 1 to 2 microns. Such carbon nanotubes typically have an aspect ratio which is within the range of 80 to 180 and more typically have an aspect ratio which is within the range of 90 to 150. The carbon nanotubes used in making the thermoplastic polymer compositions of this invention preferably have an aspect ratio which is within the range of 95 to 120.
The copolymer of ethylene with a higher α-olefin used in making the thermoplastic polymer compositions of this invention has from about 0.5 weight percent to 2.5 weight percent of maleic anhydride or glycidyl methacrylate grafted onto it. It is typically preferred for the level of maleic anhydride or glycidyl methacrylate grafted onto the backbond of the polymer to be within the range of 0.9 weight percent to 1.5 weight percent. The higher α-olefin will typically contain from 2 to about 12 carbon atoms and will preferably contain form 6 to 10 carbon atoms. The α-olefin will preferably be 1 -octene and it is normally preferred for the grafting agent to be maleic anhydride. Fusabond® MN-493D is a maleic anhydride grafted ethylene-octene copolymer having a melting point of 48° C. and a density of 0.87 which is commercially available from DuPont that can be used in the practice of this invention.
The functionalized rubbery polymer will generally be a compatibilizing ethylene copolymer of the formula E/X/Y, where E is about 55-75%, X is about 15-35%, and Y is about 2-15% by weight of the compatibilizing ethylene copolymer, and E is ethylene, X is an α,β-ethylenically unsaturated monomer derived from at least one of alkylacrylate, alkylmethacrylate, alkyl vinyl ether, carbon dioxide, sulfur dioxide, or mixtures thereof, where the alkyl groups contain 1- 12 carbon atoms, such as vinyl acetate, methylacrylate, butylacrylate, and methyl vinyl ether. X can, for example, be a moiety derived from at least one of alkyl acrylate, alkyl methacrylate, alkyl vinyl ether, carbon monoxide, sulfur dioxide, or mixtures thereof. More specifically, X can, for example, consist of 0-35 weight percent of a moiety derived from at least one alkyl acrylate, alkyl methacrylate, or mixtures thereof where the alkyl groups contain 1-8 carbon atoms. Y is an α,β-ethylenically unsaturated monomer containing a reactive group, such as epoxide, maleic anhydride, isocyanate, or oxazoline, for example, that forms a covalent bond with said first polymeric component. In one preferred embodiment, Y is selected from the group consisting of glycidyl methacrylate and glycidyl acrylate, maleic anhydride, and isocyanato-ethylmethacrylate.
The functionalized rubbery polymer will typically contain repeat units that are derived from an acrylate monomer of the structural formula:




wherein R represents a hydrogen atom, an alkyl group containing from 1 to about 8 carbon atoms, or a moiety containing an epoxy group, and wherein R1 represents a hydrogen atom or an alkyl group containing from 1 to about 8 carbon atoms. Some representative examples of monomers that can be used include methyl methacrylate, butyl acrylate, dimethylsiloxane. In many cases, R will represent an alkyl group containing from 1 to 4 carbon atoms. The moiety containing an epoxy group will typically be of the structural





wherein n represents an integer from 1 to about 6. In most cases, n will represent 1.

The functionalized rubbery polymer will generally also contain repeat units that are derived from a conjugated diolefin monomer, such as 1,3-butadiene or isoprene, a vinyl aromatic monomer, such as styrene or α-methyl styrene, a monoolefin monomer, such as ethylene or propylene, and/or a dialkylsiloxane monomer, such as dimethylsiloxane.
The functionalized rubbery polymer can optionally contain repeat units in its backbone which are derived from an anhydride group containing monomer, such as maleic anhydride. In another scenario, the functionalized rubbery polymer can contain anhydride moieties which are grafted onto the polymer in a post polymerization step. Lotader® 8900 is a terpolymer of ethylene, methyl methacrylate and glycidyl methacrylate that can be used as the functionalized rubbery polymer in the practice of this invention.
The acrylic based core-shell polymer will typically have an acrylic core and a shell that is comprised of polymethylmethacrylate. Durastrength®440 is core-shell acrylic based impact modifier that can be used as the acrylic based core-shell polymer in the practice of this invention.
The lubricant used in making the thermoplastic polymer compositions of this invention is either high density polyethylene or a polyester wax, such as Glycolube wax. It is frequently preferred to use a combination of high density polyethylene and a polyester wax in making the thermoplastic polymer compositions of this invention. For example, from 0.5 weight percent to 6 weight percent of polyester wax can be used as a lubricant in conjunction with 0.5 weight percent to 3 weight percent of high density polyethylene which is used to improve surface finishing characteristics.
The thermoplastic polymer compositions of this invention are made by a two step process. In the first step a portion of the polyethylene terephthalate glycol copolymer is mixed with the carbon nanotubes and optionally additional components of the composition being made. The first mixing step results in the production of a PETG/carbon nanotube premix. Then in the second step additional polyethylene terephthalate glycol copolymer, the grafted copolymer of ethylene with a higher α-olefin, the functionalized rubbery polymer, the acrylic based core-shell polymer, and the lubricant selected from the group consisting of high density polyethylene and polyester wax are dispersed throughout the PETG/carbon nanotube premix made in step (1). In this mixing procedure from 25 weight percent to 70 weight percent of the total constituents of the thermoplastic polymer composition are added in step (1) to make the premix. It is typically preferred for from 30 weight percent to 55 weight percent of the total constituents of the thermoplastic polymer composition to be added in step (1) to make the premix.
This mixing will typically be done by melt blending the components of the thermoplastic polymer composition. This can be done in a suitable mixing device for melt blending, such as a single or twin screw extruder or multiple mixing devices with controlled specific energy input via control of feed rate (15 to 95% torque), RPM (60 to 900 rpm), process temperature and residence time distribution. The specific energy input will typically be within the range of 0.15 to 0.5 kilowatt hours per kilogram and will more typically be within the range of 0.2 to 0.4 kilowatt hours per kilogram.
The thermoplastic polymer compositions of this invention will typically contain (1) the polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent of the carbon nanotubes, (3) from 2 weight percent to 30 weight percent of the copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of the functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of the acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of the lubricant selected from the group consisting of high density polyethylene and polyester wax. It should be noted that the polyethylene terephthalate glycol copolyester makes up the balance of the composition and that all weight percentages are based upon the total weight of the thermoplastic polymer composition. The thermoplactic polymer compositions of this invention will preferably contain (1) the polyethylene terephthalate glycol copolyester, (2) from 1.5 weight percent to 5 weight percent of the carbon nanotubes, (3) from 4 weight percent to 25 weight percent of the copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 2 weight percent to 8 weight percent of the functionalized rubbery polymer, (5) from 2 weight percent to 8 weight percent of the acrylic based core-shell polymer, and (6) from 0.8 weight percent to 4 weight percent of the lubricant selected from the group consisting of high density polyethylene and polyester wax. The thermoplactic polymer compositions of this invention will most preferably contain (1) the polyethylene terephthalate glycol copolyester, (2) from 2 weight percent to 4 weight percent of the carbon nanotubes, (3) from 6 weight percent to 15 weight percent of the copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 3 weight percent to 6 weight percent of the functionalized rubbery polymer, (5) from 3 weight percent to 6 weight percent of the acrylic based core-shell polymer, and (6) from 1 weight percent to 3 weight percent of the lubricant selected from the group consisting of high density polyethylene and polyester wax. This thermoplastic polymer composition can optionally contain small amounts (level of less than about 1 weight percent) of thermal stabilizers, UV stabilizers, antioxidants, and/or flame retardants.
The thermoplastic polymer compositions of this invention can then be thermoformed into disk drive head suspension assembly trays of various desired designs. Disk drive head suspension assembly trays that can be made by thermoforming the thermoplastic polymer compositions of this invention are described in U.S. Pat. No. 7,191,512 and U.S. Pat. No. 7,360,653. The teachings of U.S. Pat. No. 7,191,512 and U.S. Pat. No. 7,360,653 are incorporated herein by reference for the purpose of illustrating disk drive head suspension assembly trays that can be beneficially made by thermoforming the thermoplastic polymer compositions of this invention.
This invention is illustrated by the following examples that are merely for the purpose of illustration and are not to be regarded as limiting the scope of the invention or the manner in which it can be practiced. Unless specifically indicated otherwise, parts and percentages are given by weight.
EXAMPLE 1
The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at a rate of 350 rpm and a set temperature profile of 35° C. (feed), 230° C. (Zone 2), 255° C. (Zone 3), 260° C. (Zone 4), 260° C. (Zone 5), 260° C. (Zone 6), 260° C. (Zone 7), 255° C. (Zone 8), 255° C. (die), was charged with 77.8 parts of Skygreen PETG, 3.0 parts of Lotader 8900 terpolymer of ethylene, methyl methacrylate and glycidyl methacrylate, 3.0 parts of Durastrength®400 core-shell acrylic based impact modifier, 0.2 parts of phenolic antioxidant, 6.0 parts of Nanocyl 7000 multi-walled carbon nanotubes (9.5 nanometer diameter, 1.5 micron length, and an aspect ratio of  ̃100), 3.0 parts of cyclic polybutylene terephthalate, 2.0 parts of high density polyethylene, and 5 parts of Fusabond® MN-493D polyethylene-polyoctene copolymer grafted with maleic anhydride. This mixing procedure resulted in the production of a PETG/carbon nanotube premix.
In a subsequent mixing step the extruder was charged with an additional 47 parts of Skygreen PETG, an additional 4.0 parts of Lotader 8900 terpolymer of ethylene, methyl methacrylate and glycidyl methacrylate, an additional 3.0 parts of Durastrength®400 core-shell acrylic based impact modifier, 38 parts of the PETG/carbon nanotube premix, 1.0 parts of Glycolube P polyester wax, an additional 8 parts of Fusabond( MN-493D polyethylene-polyoctene copolymer grafted with maleic anhydride, and an additional 1 part of high density polyethylene.
Characterization of the thermoplastic polymer composition made in this experiment show that it had excellent characteristics for being thermoformed into electrically conductive packaging for electronic components, such as disk drive head suspension assembly trays. More specifically, the polymer compound made in this experiment was determined to have the characteristics shown in the Table below:








TABLE 1





Characteristic
Value







Surface resistivity
2.6 × 105 Ω/sq.


Izod impact strength at 23° C.
2.96 foot-pounds per inch


Flexural modulus (stiffness)
1,215.9 MPa


Tensile strength at break
22 MPa


Processability (sheet extrusion and
Excellent


thermoformability);


Retention of characteristics from (1) to (5)
Excellent


after sheet extrusion and thermoforming









EXAMPLES 2-8
In the following experiments thermoplastic polymer compositions were made utilizing the general procedure described in Example 1. However, the components used and the amounts of these components were varied as shown in Tables 2 and 3. The characteristics of this series of thermoplastic polymer compositions are also depicted in Tables 2 and 3.
Carbon nanotube masterbatch formulations were made in the first mixing step. In the following tables these carbon nanotube masterbatches are designated by an asterisk (*) and includes all of the materials identified above them in the table. Materials which were subsequently added to the carbon nanotube masterbatches are in the rows following the items designated with asterisks in the tables. The materials used in the following Examples are as follows:













PETG (Skygreen)
Polyethylene terephthalate glycol


HDPE 511051
Polycarbonate with melt flow index of 25



grams per 10 minutes at 190° C. and



2.16 kg


C150P, NC7000,
Multi-walled carbon nanotubes


2040 CNT


CBT100
Cyclic polyethylene terephthalate


Lotader 8900, Lotader
Terpolymer of ethylene, methyl methacrylate


4700
and glycidyl methacrylate


Glycolube P
Polyester wax


D440
Core-shell acrylic based impact modifier


PBS 2010
Polyether sulfone


PP/LDPE Blend
Blend of polypropylene with low density



polyethylene


TOHO A201
Carbon fiber


PBT CX11051
Medium viscosity polybutylene terephthalate


Printex XE2
High surface area conductive carbon black


Fusabond 493D
Polyethylene-polyoctene copolymer grafted



with maleic anhydride


Fusabond 226DE
Polyethylene graft maleic anhydride


AO 1010
Phenolic antioxidant


A0 626
Phosphate antioxidant


AO 412S
Amine antioxidant


Surlyn ® 8920
Ethylene methacrylic acid plastic (EMMA)


Entira MK400, Sunova
Inherently dissipated polymer


80HP, Pelestat NC 6321


APET 5005
Amorphous polyethylene terephthalate


Sodium stearate
lubricant


Kraton 1901X
Styrene ethylene butadiene styrene grafted with



maleic anhydride


Pearlthane D11T93
Thermoplastic polyurethane


Ninor
Stabilizer


Bruno Bock PETMP
Thiol based crosslinker


PC 1225L
High density polyethylene with melt flow index



of 10 grams per 10 minutes at 300° C.



and 1.2 kg


Engage 8180
Polyolefin plastomer


LDPE and LDPE NA520
Low density polyethylene


Bayon YM312, CYRO
Acrylic polymer additive


H15


LLDPE (120 FPLDPE)
Linear low density polyethylene


CB900
Medium surface area carbon black









The thermoplastic polymer compositions made in this series of experiments were prepared utilizing a ZE 25 twin screw extruder (L/D=44). The main feeder of the ZE 25 twin screw extruder was operated at a rate of 400 rpm and with a set temperature profile of 40° C. (feed), 260° C. (Zone 2), 285° C. (Zone 3), 300° C. (Zone 4), 310° C. (Zone 5), 310° C. (Zone 6), 290° C. (Zone 7), 290° C. (Zone 8), and 285° C. (die). The components used in making such thermoplastic polymer compositions and the levels utilized in reported in the following tables.







TABLE 2







CP 292 (PETG Antistat - HSA Trays)









Material
EXAMPLE 2
EXAMPLE 3












PETG Skygreen
42
47


Lotader 8900
5
4


D440
5
4


CP 290 X1*
38
38


Glycolube P
1
1


Fusabond 493D
8
5


HDPE 511051
1
1







Properties









Tensile Modulus (Mpa)
1036.3
1155.5


Tensile Str. @ YLD (Mpa)
26.4
30.2


Tensile Str. @ BRK (Mpa)
20.5
22


Tensile Str. @ BRK (%)
22.3
23.8


Flex Modulus (Mpa)
1073.8
1215.9


Flex Stress (Mpa)
37.4
42.1


Izod Impact @RT (ft-lb/in)
9.48 PB
2.96 (3CB)




6.76 (2PB)


Resistance - Strand (Ohms/sq)
1.80E+04
2.60E+04


Resistance - Tensile (Ohms/sq)
8.30E+09
3.66E+09
















TABLE 3







CP 300 (PETG Antistat - HSA Trays)













Material
EXAMPLE 4
EXAMPLE 5
EXAMPLE 6
EXAMPLE 7
EXAMPLE 8
EXAMPLE 9
















PETG Skygreen
79.8
30
37
25
35
79.8


Lotader 8900
3
5
5
5
5
3


D440
3
5
5
5
5
3


AO 1010
0.2




0.2


CP 300 X6*




45


C150P





6


CP 300 X1*

50
43
55


NC 7000
6


CBT 100
1




1


HDPE 511051
2
1
1
1
1
2


Fusabond 493D
5
8
8
8
8
5


Glycolube P

1
1
1
1







Properties













Tensile Modulus
1660.3
1085
1093.2
1100.6
1186.8



(Mpa)


Tensile Str. @
39.2
27.1
27.3
26.3
30.2


YLD (Mpa)


Tensile Str. @
27.5
25.3
27.6
21.8
28.7


BRK (Mpa)


Tensile Str. @
13.3
130
156.5
69.6
113


BRK (%)


Flex Modulus
1916.2
1274.5
1229.4
1226.9
1214.9


(Mpa)


Flex Stress
59
40.9
40.1
39.6
38.4


(Mpa)


Izod Impact
1.89 CB
15.9 NB
15.4 NB
12.2 NB
17.6 NB


@RT (ft-lb/in)


HDT @66 psi
66.1
63.9
66
64.2
68.4


(° C.)


Resistance -
7.37E+03
7.03E+11
2.09E+11
8.27E+05
1.6E+04


Strand


(Ohms/sq)


Resistance -
4.82E+09
6.74E+12
 7.6E+12
5.52E+12


Tensile


(Ohms/sq)









COMPARATIVE EXAMPLES 10-139
In this series of experiments thermoplastic polymer compositions were again made utilizing the general procedure described in Example 1. The components used and the amounts of these components were varied as shown in Table 4-40. The characteristics of this series of thermoplastic polymer compositions are also depicted in Tables 4-40. As can be seen, the properties of the polymer compositions made in this series of experiments were not optimal for utilization in manufacturing head suspension trays for one or more reasons.







TABLE 4







CP 197 (PETG Antistat)












EXAMPLE
EXAMPLE


Material
EXAMPLE 10
11
12













PETG Skygreen
75
70
71


Lotader 8900


2


Surlyn 8920


2


Entira MK 400
25
30
25







Properties










Tensile Modulus (Mpa)
1247
1146
1059


Tensile Str. @ YLD (Mpa)
21
28.3
28


Tensile Str. @ BRK (Mpa)
24
28.3
28


Tensile Str. @ BRK (%)
2.3
3.1
3.4


Flex Modulus (Mpa)
1332
1154
1036


Flex Stress (Mpa)
50
46.3
41.5


Izod Impact @RT (ft-lb/in)
0.26 CB
0.43 CB
0.45 CB


Resistance (ohms/sq)
3.04E+12
3.04E+12
2.44E+12
















TABLE 5







CP 198 (PETG Antistat)












EXAMPLE
EXAM-
EXAMPLE
EXAM-


Material
13
PLE 14
15
PLE 16














APET 5005

75
71
69


PETG Skygreen
69


Lotader 8900
2

2
2


D440
2


2


Surlyn 8920
2

2
2


Entira MK 400
25
25
25
25







Properties











Resistance - Strand
1.62E+13
2.64E+12
5.08E+12
1.90E+12


(ohms/sq)
















TABLE 6







CP 199 (PETG & APET Antistat)














EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE


Material
17
18
19
20
21
22
















APET 5005



75
71
69


PETG
75
71
69


Skygreen


Lotader 8900

2
2

2
2


D440


2


2


Surlyn 8920

2
2

2
2


Sunova 80HP
25
25
25
25
25
25







Properties













Resistance -
1.02E+12
1.21E+12
4.47E+12
1.90E+12
1.21E+12
2.52E+12


Strand


(ohms/sq)
















TABLE 7







CP 202 (PETG & APET Antistat)














EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-



PLE
PLE
PLE
PLE
PLE
PLE


Material
23
24
25
26
27
28
















PETG
69.5
65.5
63
63
64.5
64.5


Skygreen


Lotader

2
3.5


8900


Surlyn 8920

2
3
3

5


Na Stearate
0.5
0.5
0.5
0.5
0.5
0.5


Sunova
30
30
30
30
30
30


80HP


Kraton



3.5
5


1901X





No Properties













TABLE 8







CP 203 (PETG Antistat)













EXAM-
EXAM-
EXAM-
EXAM-
EXAM-


Material
PLE 29
PLE 30
PLE 31
PLE 32
PLE 33















PETG Skygreen
65.5
65.5
65.5
65
65


Lotader 8900
2
2
2


Surlyn 8920
2
2
2
5
5


Na Stearate
0.5
0.5
0.5


Pelestat NC 6321
30


Sunova 80HP

30
30
30
30





No Properties













TABLE 9







CP 204 (PETG Antistat)










Material
EXAMPLE 34














PETG Skygreen
70.8



Lotader 8900
2



D440
2



Pearlthane D11T93
25



AO 1010
0.2







No Properties













TABLE 10







CP 205 (PETG Antistat)














EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-



PLE
PLE
PLE
PLE
PLE
PLE


Material
35
36
37
38
39
40
















Lotader

1
2

1
2


8900


Surlyn 8920

1
2

1
2


Sunova
25
25
25
30
30
30


80HP


CP 204 X1*
75
73
71
70
68
66





No Properties













TABLE 11







CP 206 (PETG Antistat)










Material
EXAMPLE 41
EXAMPLE 42
EXAMPLE 43













PETG Skygreen
10
20
30


Lotader 8900
1
1
1


Surlyn 8920
1
1
1


Sunova 80HP
30
30
30


CP 201 X1*
58
48
38





No Properties













TABLE 12







CP 207P (PETG Antistat)










Material
EXAMPLE 44














PETG Skygreen
20



Lotader 8900
1



Surlyn 8920
1



Sunova 80HP
30



CP 201 X1*
48







Properties










Izod Impact @RT (ft-lb/in)
16.0 NB



Resistance - Disk (ohms/sq)
3.07E+10

















TABLE 13







CP 208 (APET Antistat)










Material
EXAMPLE 45














APET 5005
70.8



Lotader 8900
2



D440
2



Pearlthane D11T93
25



AO 1010
0.2







No Properties













TABLE 14







CP 209 (APET Antistat)











Material
EXAMPLE 46
EXAMPLE 47















APET 5005
20




Lotader 8900
1
1



Surlyn 8920
1
1



Sunova 80HP
30
30



CP 204 X1*

20



CP 208 X1*
48
48







No Properties













TABLE 15







CP 210P (APET Antistat)










Material
EXAMPLE 48














APET 5005
70.8



Lotader 8900
2



D440
2



Pearlthane D11T93
25



AO 1010
0.1



AO 626
0.1







No Properties













TABLE 16







CP 211P (APET Antistat)










Material
EXAMPLE 49














Lotader 8900
1



Surlyn 8920
1



Sunova 80HP
30



AO 412S
0.1



Ninor
0.1



CP 204 X1*
20



CP 210 X1*
47.8







Properties










Tensile Modulus (Mpa)
394



Tensile Str. @ YLD (Mpa)
11.3



Tensile Str. @ BRK (Mpa)
11



Tensile Str. @ BRK (%)
11.2



Flex Modulus (Mpa)
452



Flex Stress (Mpa)
18.4



Izod Impact @RT (ft-lb/in)
0.39 HB



HDT @66 psi (° C.)
50.9



Resistance - Bars (Ohms/sq)
1.14E+10

















TABLE 17







CP 213P (APET CNT)










Material
EXAMPLE 50














APET 5005
95.8



Lotader 8900
1



NC 7000
3



AO 412S
0.1



Ninor
0.1







Properties










Tensile Modulus (Mpa)
2623



Tensile Str. @ YLD (Mpa)
52.9



Tensile Str. @ BRK (Mpa)
52.9



Tensile Str. @ BRK (%)
2.7



Flex Modulus (Mpa)
2888



Flex Stress (Mpa)
101



Izod Impact @RT (ft-lb/in)
0.28



Specific Gravity
1.383

















TABLE 18







CP 214 (PETG & PC CNT)











EXAMPLE
EXAMPLE
EXAMPLE


Material
51
52
53













PETG Skygreen
95




PC 1225L

95.5
93


Lotader 8900
1
1
1


NC 7000
4
3.5
6







Properties









Tensile Modulus (Mpa)
1841



Tensile Str. @ YLD (Mpa)
50.8


Tensile Str. @ BRK (Mpa)
30


Tensile Str. @ BRK (%)
17.6


Flex Modulus (Mpa)
2326


Flex Stress (Mpa)
75.5


Izod Impact @RT (ft-lb/in)
1.07


Specific Gravity
1.2823
















TABLE 19







CP 228 (APET Antistat)












EXAM-
EXAM-
EXAM-
EXAM-



PLE
PLE
PLE
PLE


Material
54
55
56
57














APET 5005
95.9
95.9
93.8
93.9


Lotader 8900
2
2
2
2


D440
2

2
2


Surlyn 8920

2
2
2


Bruno Bock PETMP



0.1


AO 412S
0.1
0.1
0.1
0.1







Properties











Tensile Modulus (Mpa)
1992.4
2157.4
2031.8
2101.1


Tensile Str. @ YLD (Mpa)
49
59.2
60
60.4


Tensile Str. @ BRK (Mpa)
49.4
58.9
38
42.2


Tensile Str. @ BRK (%)
3.3
4.3
20.6
13.8


Flex Modulus (Mpa)
2147.5
2433.3
2201.1
2361.7


Flex Stress (Mpa)
81.9
94.1
88
87.8


Izod Impact @RT (ft-lb/in)
0.85 CB
0.76 CB
0.77 CB
0.64 CB
















TABLE 20







CP 229 (APET Antistat)











EXAMPLE
EXAMPLE
EXAMPLE


Material
58
59
60













APET 5005
89.9
86.9
79.9


Lotader 8900
5
5
5


D440
5
8
5


Pearlthane D11T93


10


AO 412S
0.1
0.1
0.1







Properties










Tensile Modulus (Mpa)
1580.2
1633.7
1575.6


Tensile Str. @ YLD (Mpa)
41.9
47.6
40.6


Tensile Str. @ BRK (Mpa)
28
30


Tensile Str. @ BRK (%)
175
21.9
19.4


Flex Modulus (Mpa)
1879.2
1681.4
1587.5


Flex Stress (Mpa)
60
61.9
57.6


Izod Impact @RT (ft-lb/in)
3.36 CB
2.99 CB
1.91 CB
















TABLE 21







CP 230P (APET Antistat Base)










Material
EXAMPLE 61














APET 5005
87.9



Lotader 8900
7



D440
5



AO 412S
0.1







No Properties













TABLE 22







CP 231P (APET CNT)










Material
EXAMPLE 62
EXAMPLE 63
EXAMPLE 64













Lotader 8900
2.5
2.5
2.5


CP 230P*
94.9
94.9
94.5


C150P
2.6
3
3.42


CBT 100


1.84


HDPE 511051


0.92


Glycolube P


0.92





No Properties













TABLE 23







CP 232P (APET CNT)










Material
EXAMPLE 65














Lotader 8900
2.5



CP 230P*
90



2040 CNT
3.6



CBT 100
2



HDPE 511051
1



Glycolube P
0.9







Properties










Tensile Modulus (Mpa)
1636.4



Tensile Str. @ YLD (Mpa)
41



Tensile Str. @ BRK (Mpa)
41.1



Tensile Str. @ BRK (%)
4.2



Flex Modulus (Mpa)
1874.2



Flex Stress (Mpa)
67.9



Izod Impact @RT (ft-lb/in)
0.69 CB



Specific Gravity
1.2988

















TABLE 24







CP 237 (APET Antistat Base)














EXAM-
EXAM-
EXAM-
EXAM-
EXAM-
EXAM-



PLE
PLE
PLE
PLE
PLE
PLE


Material
66
67
68
69
70
71
















APET 5005
87.9
78.9
78.9

57.9
77.9


Lotader 8900
7
6
5
5
5
5


D440
5
15
5
20
7
7


AO 412S
0.1
0.1
0.1
0.1
0.1
0.1


PC 1225L



75


Engage 8180


11


CP 237 X4*




30


LDPE





10







Properties









Tensile
1852.3



Modulus


(Mpa)


Tensile Str. @
52.7


YLD (Mpa)


Tensile Str. @
50.4


BRK (Mpa)


Tensile Str. @
8.3


BRK (%)
















TABLE 25







CP 239 (APET Antistat Base)













EXAM-
EXAM-
EXAM-
EXAM-



Material
PLE 72
PLE 73
PLE 74
PLE 75
EXAMPLE 76















APET 5005

57.9
43.9




Lotader 8900
5
5
8


D440
20
7
8
2
2


AO 412S

0.1
0.1


PC 1225L
75


NC 7000



5
5


CP 239 X1*

30
40


CP 239 X2*



93


CP 239 X3*




93





No Properties













TABLE 26







CP 253 (PETG Antistat - HSA Trays)













EXAM-
EXAM-
EXAM-
EXAM-
EXAM-


Material
PLE 77
PLE 78
PLE 79
PLE 80
PLE 81















PETG Skygreen
70.8
19.8





Lotader 8900
2
1


D440
2


Pearlthane D11T93
25


AO 1010
0.2


Surlyn 8920

1


Sunova 80HP

30

30
30


CP 253 X1*

48

69
67


CB 900

0.2


CP 253 X2*


98


NC 7000


2
1


Bayon YM312




3





No Properties













TABLE 27







CP 255 (PETG Antistat - HSA Trays)













EXAM-
EXAM-
EXAM-
EXAM-
EXAM-


Material
PLE 82
PLE 83
PLE 84
PLE 85
PLE 86















PETG Skygreen
69.8






Lotader 8900
2
1
1
1
1


D440
2
3


Pearlthane D11T93
25


AO 1010
0.2


Surlyn 8920
1


Sunova 80HP

30
30
30
30


CP 253 X1*

66
66
65
65


NC 7000



1
1


Bayon YM312



3


CYRO H15


3

3





No Properties













TABLE 28







CP 256 (PETG Antistat - HSA Trays)












EXAM-
EXAM-
EXAM-
EXAM-



PLE
PLE
PLE
PLE


Material
87
88
89
90














PETG Skygreen
93


16.8


Lotader 8900
2


3


D440



3


Pearlthane D11T93



15


AO 1010



0.2


Surlyn 8920



2


Sunova 80HP


CP 255 X1*

60
40


CP 256 X1*

40
60
60


NC 7000
5







Properties










Tensile Modulus (Mpa)
1577.4
1835.3
1505.7


Tensile Str. @ YLD (Mpa)
42.7
44.9
40.7


Tensile Str. @ BRK (Mpa)
33.2
44.5
40.3


Tensile Str. @ BRK (%)
99
3.3
3.8


Izod Impact @RT (ft-lb/in)
1.16 CB
1.34 CB
1.68 CB


MI @240 C., 5.0 Kg
25.03
16.07
10.63


(g/10 min)


Resistance (Ohms/sq)
4.07E+12
8.39E+09
1.65E+09
















TABLE 29







CP 265 (PETG Antistat - HSA Trays)














EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE


Material
91
92
93
94
95
96
















PETG
87
11.8

16.8
13



Skygreen


Lotader 8900
2
3
2
3
3
3


D440
3
3
2
3
3
3


Pearlthane

15
13.8
15
15


D11T93


AO 1010

0.2
0.2
0.2
0.2
0.2


Surlyn 8920

2
2
2
2
2


CP 255 X1*





31.8


CP 265 X1*

65
80
60
60
60


CBT 100
2



3.8


C150P
6







Properties













Tensile

1549.8
1714.8
1464.5




Modulus


(Mpa)


Resistance -

3.6E+06
1.5E+03
2.9E+03

Mid-HighE+03


Strand


(Ohms/sq)
















TABLE 30







CP 266 (PETG Antistat - HSA Trays)










Material
EXAMPLE 97














PETG Skygreen
11.8



Lotader 8900
3



D440
3



AO 1010
0.2



Surlyn 8920
2



CP 255 X1*
20



CP 265 X1*
60







Properties










Tensile Modulus (Mpa)
1744.5



Tensile Str. @ YLD (Mpa)
41.6



Tensile Str. @ BRK (Mpa)
35.7



Tensile Str. @ BRK (%)
7.8



Flex Modulus (Mpa)
1800.8



Flex Stress (Mpa)
60.3

















TABLE 31







CP 269 (PETG Antistat - HSA Trays)














EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE


Material
98
99
100
101
102
103
















PETG
87
11.8
11.8

72
52.5


Skygreen


Lotader 8900
2
3
3

3
3


D440
3


CBT 100
2



3.8


AO 1010

0.2
0.2

0.2
0.2


Surlyn 8920

2
2


LDPE NA520


15
85


PP 6310

15


CP 269 X1*

65
65


CP 269 X4*




15
40


C150P
6


10
3
1.25


Lotader 4700

3


Fusabond


3
5
3
3


226DE







Properties













Tensile

1340.5
1047.5

1210.8
849.4


Modulus


(Mpa)


Tensile Str. @

30.6
25

32
24.2


YLD (Mpa)


Tensile Str. @

27.3
21.2

23.1
23.8


BRK (Mpa)


Tensile Str. @

6.11
7.4

39.2
5.6


BRK (%)


Flex Modulus

1554.3
1197

1360
769.9


(Mpa)


Flex Stress

46.7
39.4

47
30.4


(Mpa)


Izod Impact

1.13 CB
1.14 CB

1.07 CB
0.94 PB


@RT (ft-


lb/in)


MI @240 C,

7.3
3.6

6.7
0 No Flow


5.0 Kg


(g/10 min)


Resistance -

 1.6E+04
 2.0E+04
5.3E+08
4.40E+12


Strand


(Ohms/sq)


Resistance -

5.26E+12
3.99E+11

2.7E+10
1.73E+12


Probe




(2)


(Ohms/sq)




4.1E+07







(1)
















TABLE 32







CP 270 (PETG Antistat - HSA Trays)












EXAM-
EXAM-
EXAM-
EXAM-



PLE
PLE
PLE
PLE


Material
104
105
106
107














PETG Skygreen
8.8
7.8
21.8
30.3


Lotader 8900
3
3
3
3


D440
3
3
3
3


AO 1010
0.2
0.2
0.2
0.2


Surlyn 8920
2
2
2
2


CP 255 X1*
20
20
20
20


CP 265 X1*
60
60
50
41.5


HDPE 511051
3
2


Glycolube P

2







Properties











Tensile Modulus (Mpa)
1507.8
1474
1509.7
1382.1


Tensile Str. @ YLD
38.2
36.4
35.9
36.6


(Mpa)


Tensile Str. @ BRK
28.3
29.9
32.8
25.9


(Mpa)


Tensile Str. @ BRK (%)
11.7
8.9
5.9
13.1


Flex Modulus (Mpa)
1850.3
1721.2
1899.7
1624.3


Flex Stress (Mpa)
60.7
57
59.3
56.1


Izod Impact @RT
1.06 CB
0.77 CB
0.53 CB
0.86 CB


(ft-lb/in)


MI @240 C., 5.0 Kg
8.3
5.3
9.8
31.5


(g/10 min)


Resistance - Strand
4.16E+03
2.36E+03
4.48E+03
8.76E+05


(Ohms/sq)


Resistance - Probe
4.60E+06
3.99E+07
7.61E+08
3.98E+12


(Ohms/sq)
















TABLE 33







CP 273 (PETG Antistat - HSA Trays)










Material
EXAMPLE 108














PETG Skygreen
28



Lotader 8900
3.8



D440
3



AO 1010
0.2



CP 255 X1*
20



CP 265 X1*
42



HDPE 511051
3







Properties










Tensile Modulus (Mpa)
1551.4



Tensile Str. @ YLD (Mpa)
37.4



Tensile Str. @ BRK (Mpa)
37.4



Tensile Str. @ BRK (%)
3.3



Flex Modulus (Mpa)
1666



Flex Stress (Mpa)
55.2



Izod Impact @RT (ft-lb/in)
1.19 CB



Resistance - Strand (Ohms/sq)
1.51E+06

















TABLE 34







CP 288 (PETG Antistat - HSA Trays)













EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE


Material
109
110
111
112
113















PETG Skygreen
77.8
32
32
33
42


Lotader 8900
3
4

5
5


D440
3
4

2
5


AO 1010
0.2


Pearlthane 11T93



15


CP 255 X1*

20
20


CP 288 X1*

38
38
38
38


NC 7000
6


CBT 100
3


HDPE 511051
2
1
1
1
1


Fusabond 493D
5

8
5
8


Glycolube P

1
1
1
1







Properties












Tensile Modulus

1444.6
1350
1135.3
996.9


(Mpa)


Tensile Str. @ YLD

37.8
34.9
29.6
26.9


(Mpa)


Tensile Str. @ BRK

23.3
22.5
20.6
21.3


(Mpa)


Tensile Str. @ BRK

13
11.1
21.2
31.3


(%)


Flex Modulus (Mpa)

1531.1
1425.5
1202.9
1032.8


Flex Stress (Mpa)

55.3
50.4
41.8
37


Izod Impact @RT (ft-

3.41 CB
2.57 CB
4.43 CB
25.3 NB


lb/in)


Resistance - Strand

7.43E+05
1.23E+05
5.17E+04
4.17E+04


(Ohms/sq)


Resistance - Tensile

4.72E+12
1.82E+11
1.57E+12
5.68E+12


(Ohms/sq)
















TABLE 35







CP 290 (PETG Antistat - HSA Trays)













EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE


Material
114
115
116
117
118















PETG Skygreen
77.8
47
42
52
52


Lotader 8900
3
4
5
3


D440
3
4
5


AO 1010
0.2


CP 290 X1*

38
38
38
38


NC 7000
6


CBT 100
3


HDPE 511051
2
1
1
1
1


Fusabond 493D
5
5
8
5
8


Glycolube P

1
1
1
1







Properties












Tensile Modulus

1171.9
1015.2
1233.8
1279.7


(Mpa)


Tensile Str. @ YLD

31.3
27.5
34.8
36.9


(Mpa)


Tensile Str. @ BRK

23
21.8
23.9
24.4


(Mpa)


Tensile Str. @ BRK

20.8
26.7
16.8
13.3


(%)


Flex Modulus (Mpa)

1175
1050.7
1305.5
1386.7


Flex Stress (Mpa)

42.1
37.5
47.3
50.1


lzod Impact @RT (ft-

3.23 CB
8.55 PB
2.05 CB
1.99 CB


lb/in)


Resistance - Strand

1.57E+04
1.77E+04
1.40E+04
4.57E+04


(Ohms/sq)


Resistance - Tensile

5.85E+11
9.70E+10
7.62E+10
2.88E+11


(Ohms/sq)
















TABLE 36







CP 291 (PETG Antistat - HSA Trays)









Material
EXAMPLE 119
EXAMPLE 120












PETG Skygreen
74.1
76.4


Lotader 8900
4
4


D440
6
6


NC 7000
2.3


CBT 100
1.1
1.1


HDPE 511051
1.5
1.5


Fusabond 493D
10
10


Glycolube P
1
1







Properties









Tensile Modulus (Mpa)
1085.1
1069.9


Tensile Str. @ YLD (Mpa)
28.1
28.4


Tensile Str. @ BRK (Mpa)
20.4
30.1


Tensile Str. @ BRK (%)
19.6
304.1


Flex Modulus (Mpa)
1162.8
1114.7


Flex Stress (Mpa)
40.3
38.7


Izod Impact @RT (ft-lb/in)
6.91 NB
19.2 NB


Resistance - Tensile (Ohms/sq)
1.02E+03
6.42E+12
















TABLE 37







CP 294 (PETG Antistat - HSA Trays)














EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE


Material
121
122
123
124
125
126
















PETG
84.1
78.1
74.1
80.1
74.1
67.1


Skygreen


Lotader 8900
4

4
4
4
5


D440
6
6
6
10
10
2


NC 7000
2.3
2.3
2.3
2.3
2.3
2.3


CBT 100
1.1
1.1
1.1
1.1
1.1
1.1


HDPE 511051
1.5
1.5
1.5
1.5
1.5
1.5


Fusabond

10
10

6
5


493D


Glycolube P
1
1
1
1
1
1


Pearlthane





15


11T93







Properties













Tensile
1403.7
1369.4
1103.9
1277.4
1116.2
1117.3


Modulus


(Mpa)


Tensile Str. @
39.2
35.7
28.8
34.5
29.6
30.2


YLD (Mpa)


Tensile Str. @
25.3
23.8
20.6
23.8
21.1
20.2


BRK (Mpa)


Tensile Str. @
14.1
10.6
22.2
18.3
16.4
19


BRK (%)


Flex Modulus
1587.3
1569.4
1205.5
1541.7
1208
1291.8


(Mpa)


Flex Stress
54.2
49.2
42
52.9
42.8
44.9


(Mpa)


lzod Impact
1.27 CB
1.56 CB
2.98 CB
1.73 CB
2.63 CB
2.40 CB


@RT (ft-lb/in)


Resistance -
9.63E+04
1.02E+04
7.37E+05
1.43E+04
5.30E+05
1.11E+12


Strand


(Ohms/sq)


Resistance -
7.82E+09
1.40E+06
4.98E+12
3.94E+08
7.08E+12
1.04E+13


Tensile


(Ohms/sq)
















TABLE 38







CP 296 (PETG Antistat - HSA Trays)












EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE


Material
127
128
129
130














PETG
77.8
50
47
47


Skygreen


Lotader 8900
3
5

5


D440
3
5
5


AO 1010
0.2


CP 290 X1*

38
38
38


NC 7000
6


CBT 100
3


HDPE 511051
2
1
1
1


Fusabond 493D
5

8
8


Glycolube P

1
1
1





No Properties













TABLE 39







CP 297 (PETG Antistat - HSA Breaker Plate)












EXAM-
EXAM-
EXAM-
EXAM-



PLE
PLE
PLE
PLE


Material
131
132
133
134














PETG Skygreen
77.8
42
42
30


Lotader 8900
3
5
5
5


D440
3
5
5
5


AO 1010
0.2


LLDPE (120FPLDPE)


2


CP 297 X1*

38
38
50


NC 7000
6


CBT 100
3


HDPE 511051
2
1
1
1


Fusabond 493D
5
8
8
8


Glycolube P

1

1







Properties










Tensile Modulus (Mpa)
1015

948


Tensile Str. @ YLD
26

23.7


(Mpa)


Tensile Str. @ BRK
19.4

18.4


(Mpa)


Tensile Str. @ BRK
34.6

37.9


(%)


Flex Modulus (Mpa)
1064

986


Flex Stress (Mpa)
37

33


HDT @66 psi (° C.)
63.7

61.4


Specific Gravity
1.1805

1.1665


Resistance - Strand

2.43E+12
2.37E+12


(Ohms/sq)
















TABLE 40







CP 299 (PETG Antistat - HSA Trays)













EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE
EXAMPLE


Material
135
136
137
138
139















PETG Skygreen
85.7
83
83
78.8
79.9


Lotader 8900
4.2

4.2
4.2
4.2


D440
4.2
4.2

4.2
4.2


C150P
2.3
2.3
2.3
2.3
2.3


CBT 100
1.1
1.1
1.1
1.1


HDPE 511051
1.5
1.5
1.5
1.5
1.5


Fusabond 493D

6.9
6.9
6.9
6.9


Glycolube P
1
1
1
1
1







Properties












Tensile Modulus
1464
1383
1309.7
1211.3
1207.1


(Mpa)


Tensile Str. @ YLD
39.6
36
34.8
32.4
31.9


(Mpa)


Tensile Str. @ BRK
23.2
21.9
21.7
21.2
22.1


(Mpa)


Tensile Str. @ BRK
20.1
17.4
57.1
35.7
65.2


(%)


Flex Modulus (Mpa)
1645
1480
1375
1285
1269


Flex Stress (Mpa)
56
51
49
46
45


HDT @66 psi (° C.)
65.3
65.8
68.3
65.7
68.1


Specific Gravity
1.2423
1.221
1.2178
1.2095
1.2105









While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention.

## Claims

1. A thermoplastic polymer composition which is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.

2. A thermoplastic polymer composition as specified in claim 1 wherein the polyethylene terephthalate glycol copolyester is comprised of repeat units that are derived from terephthalic acid, ethylene glycol, and at least one additional glycol selected from the group consisting of 1,4-cyclohexanedimethanol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 2,2-dimethyl-1,3-propanediol, 1,6-hexanediol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,2-cyclohexanedimethanol, and 1,3-cyclohexanedimethanol.

3. A thermoplastic polymer composition as specified in claim 2 wherein the additional glycol is 1,4-cyclohexanedimethanol.

4. A thermoplastic polymer composition as specified in claim 3 wherein the 1,4-cyclohexanedimethanol constitutes from about 10 mole percent to about 40 mole percent of the glycol component.

5. A thermoplastic polymer composition as specified in claim 1 wherein the polyethylene terephthalate glycol copolyester has a melt viscosity which is within the range of 0.8 to 10 grams per 10 minutes.

6. A thermoplastic polymer composition as specified in claim 1 wherein the polyethylene terephthalate glycol copolyester has a melt viscosity which is within the range of 0.9 to 5 grams per 10 minutes.

7. A thermoplastic polymer composition as specified in claim 1 wherein the carbon nanotubes have a diameter which is within the range of 5 nanometers to 20 nanometers and a length which is within the range of 1 micron to 5 microns.

8. A thermoplastic polymer composition as specified in claim 1 wherein the carbon nanotubes have a diameter which is within the range of 7 nanometers to 15 nanometers and a length which is within the range of 1 micron to 3 microns.

9. A thermoplastic polymer composition as specified in claim 1 wherein the carbon nanotubes have an aspect ratio which is within the range of 80 to 180.

10. A thermoplastic polymer composition as specified in claim 8 wherein the carbon nanotubes have an aspect ratio which is within the range of 95 to 120.

11. A thermoplastic polymer composition as specified in claim 1 wherein the functionalized rubbery polymer is a terpolymer of ethylene, methyl methacrylate, and glycidyl methacrylate.

12. A thermoplastic polymer composition as specified in claim 1 wherein the carbon nanotubes are present at a level which is within the range of 1.5 weight percent to 5 weight percent.

13. A thermoplastic polymer composition as specified in claim 2 wherein the copolymer of ethylene with a higher αolefin is present at a level which is within the range of 4 weight percent to 25 weight.

14. A thermoplastic polymer composition as specified in claim 13 wherein the functionalized rubbery polymer is present at a level which is within the range of 2 weight percent to 8 weight percent.

15. A thermoplastic polymer composition as specified in claim 14 wherein the acrylic core-shell polymer is present at a level which is within the range of 2 weight percent to 8 weight percent, and wherein the lubricant is present at a level which is within the range of 0.8 weight percent to 4 weight percent.

16. A thermoplastic polymer composition as specified in claim 1 wherein the carbon nanotubes are present at a level which is within the range of 2 weight percent to 4 weight percent, wherein the copolymer of ethylene with a higher α-olefin is present at a level which is within the range of 6 weight percent to 15 weight, wherein the functionalized rubbery polymer is present at a level which is within the range of 3 weight percent to 6 weight percent, wherein the acrylic core-shell polymer is present at a level which is within the range of 3 weight percent to 6 weight percent, and wherein the lubricant is present at a level which is within the range of 1 weight percent to 3 weight percent.

17. A thermoplastic polymer composition as specified in claim 1 wherein the lubricant is a high density polyethylene.

18. A thermoplastic polymer composition as specified in claim 1 wherein the lubricant is a polyester wax.

19. A disk drive head suspension assembly tray which is comprised of an exterior frame having substantially perpendicularly adjacent sides, frame sides having essentially planar top and bottom surfaces, at least two feet, at least two foot seats, at least one support rib, and a repository that is adapted to seat and retain a disk drive head suspension, wherein the disk drive head suspension assembly tray is comprised of (1) a polyethylene terephthalate glycol copolyester, (2) from 1 weight percent to 6 weight percent carbon nanotubes, (3) from 2 weight percent to 30 weight percent of a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, (4) from 1 weight percent to 10 weight percent of a functionalized rubbery polymer, (5) from 1 weight percent to 10 weight percent of an acrylic based core-shell polymer, and (6) from 0.5 weight percent to 6 weight percent of a lubricant selected from the group consisting of high density polyethylene and polyester wax, where the polyethylene terephthalate glycol copolyester makes up the balance of the composition and wherein all weight percentages are based upon the total weight of the thermoplastic polymer composition.

20. A process for making a thermoplastic polymer composition which comprises (1) mixing a polyethylene terephthalate glycol copolymer and carbon nanotubes in a first mixing step to produce a PETG/carbon nanotube premix, and (2) mixing additional polyethylene terephthalate glycol copolymer, a copolymer of ethylene with a higher α-olefin, wherein the copolymer is of ethylene with the higher α-olefin is grafted with maleic anhydride or glycidyl methacrylate, a functionalized rubbery polymer, an acrylic based core-shell polymer, and a lubricant selected from the group consisting of high density polyethylene and polyester wax throughout the PETG/carbon nanotube premix made in step (1), wherein from 25 weight percent to 70 weight percent of the total constituents of the thermoplastic polymer composition are added in step (1) to make the premix.