ANTISTATIC THERMOPLASTIC COMPOSITIONS

Abstract: Antistatic thermoplastic compositions are provided in which about 50 to 95 wt% of a thermoplastic polymer contains about 5 to about 50 wt% of a polyvinyl alcohol copolymer. The copolymer is preferably a copolymer of vinyl acetate and poly(alkyleneoxy)acrylate in which the acetate functionality is partially or fully hydrolyzed to yield a vinyl alcohol copolymer. The thermoplastic to which antistatic properties are imparted may be filled or unfilled and include, for example, styrenics, halogenated polymers, polyesters, polyolefins, polycarbonates, polyamides, polyurethanes, ABS copolymers, SAN copolymers, polysulfones, fluoropolymers, and rubbers. In a preferred embodiment, the composition also includes a hygroscopic or water soluble inorganic or organic salt synergist for the copolymer.

Description: ANTISTATIC THERMOPLASTIC COMPOSITIONS Field of the Invention The present invention relates to filled and unfilled thermoplastic compositions which exhibit antistatic properties. More particularly, the present invention relates to filled and unfilled antistatic thermoplastic compositions with sustained ability to protect against electrostatic discharge damage. Background of the Invention Antistatic plastics having a resistivity of about 10 to about 10 12 oh /sq. surface resistivity are widely used in materials for protecting electronic components from electrostatic discharge (ESD) damage. Carbon black is the most common antistatic filler used in thermoplastic compositions. However, this resistivity range is generally difficult to achieve consistently in conductive composites due to the percolation threshold of carbon-filled thermoplastics. In addition, the carbon black in carbon-filled thermoplastics imparts a dark or black color. Accordingly, a desirable color is generally unachievable with carbon black filled materials. For these reasons, a non-carbon containing antistatic material is needed. Traditional antistatic plastics contain long chain hygroscopic agents or surfactants incorporated in the resin formulation during extrusion. The surfactants form a thin layer (referred to as "surface bloom") on the surface of the plastic and are continuously replenished by reserves within the bulk plastic. While on the surface, hygroscopic polar groups of the surfactants attract atmospheric water and create a thin electrically conducting surface for reduced generation and dissipation of static charges. The generally low concentration of the surfactants and their inability to be chemically bound to the bulk plastic affect the plastic's ability to sustain antistatic properties in various storage and use environments. In addition, the surface bloom tends to form a haze on the surface of the plastics, which affects the appearance of the plastic materials. Hygroscopic surfactants generally include tertiary amines and their ammonium salts, glycerides and sulfonamides. Advantages of these surfactants include their low cost and low use levels. However, the main disadvantages of these surfactants are their humidity dependence, i.e. the hygroscopic nature of the surfactants, and loss of effectiveness due to wear and use of the plastic materials. Description of the Prior Art U.S. Patents 4,618,648, 4,675,360 and 4,708,999 disclose modified polyvinyl alcohol compositions having good gas barrier properties comprising a copolymer of vinyl alcohol, vinyl acetate and a poly(alkyleneoxy)acrylate comonomer. The copolymer is prepared by polymerizing the vinyl acetate and poly(alkyleneoxy)acrylate monomer to yield a copolymer. The acetate functionality of the copolymer is then hydrolyzed to form a vinyl alcohol copolymer. U.S. Patents 4,588,773 and 4,775,716 disclose antistatic thermoplastic compositions comprising an ABS graft copolymer and an epihalohydrin copolymer. The ABS graft copolymer comprises a vinyl aromatic compound and an acrylonitrile compound. The epihalohydrin copolymer is a copolymer of epichlorohydrin and an alkylene oxide, for example, ethylene oxide, propylene oxide and mixtures thereof. U.S. Patent 4,719,263 discloses plastic materials, such as thermoplastics and thermosets, containing an effective amount of an epihalohydrin-containing polymer as an antistatic agent. Several thermoplastic materials are disclosed, includin polymers of acrylonitrile, butadiene, and styrene, polyamides o nylons, polyesters, polyvinylchloride, chlorinated polyinylchloride, and polycarbonates. Summary of the Invention According to the present invention, antistatic thermoplastic compositions are provided by incorporating about 5 to about 50 wt% of a polyvinyl alcohol copolymer in about 50 to about 95 wt% of a thermoplastic polymer which it is desired to provide with antistatic properties. The polyvinyl alcohol copolymer is preferably at least a partially hydrolyzed copolymer of vinyl acetate and poly(alkyleneoxy)acrylate in which the acetate functionality is hydrolyzed. Particularly preferred polyvinyl alcohol copolymers used in the antistatic thermoplastic compositions of the invention include those having the formula: ~(-CH 2 wherein R is hydrogen, methyl or ethyl; R and R are independently hydrogen, alkyl or aryl; R 4 and R5 are independently hydrogen, alkyl, aryl or aralkyl; n is 1 to about 1000; x is about 50 to 99.9 mole percent; y is 0 to about 50 mole percent; and z is about 0.001 to 50 mole percent. The alkyl groups are preferably 1 to about 20 carbons; the aryl groups are preferably about 6 to 20 carbons; and the aralkyl groups are preferably about 7 to 30 carbons. Detailed Description of the Invention According to the present invention, the thermoplastic polymers used in the antistatic thermoplastic compositions may generally be any thermoplastic polymer known to those skilled in the art. Preferably, the thermoplastic polymer is selected from styrenics, such as high-impact polystyrenes; halogenated polymers, such as polyvinyl chlorides and polyvinylidene chlorides; polyesters, such as polyethylene terephthalates and polybutylene terephthalates; polyolefins, such as polyethylenes and polypropylenes; polycarbonates; polyamides, such as nylon; polyurethanes; ABS copolymers; SAN copolymers; polysulfones; fluoropoly ers; and rubbers. It will be understood that copolymers and modified polymers of the above may also be used in the invention. The thermoplastic polymer is present in the antistatic thermoplastic composition in an amount of about 50 to 95 wt% and preferably, about 70 to 90 wt%. The thermoplastic may additionally contain various additives, fillers, reinforcements, and the like in amounts which may be readily determined by one skilled in the art depending upon the particular properties desired. Non-limiting examples of such additives include antioxidants, for example hindered phenols, such as IRGANOX*; UV stabilizers, for example hydroxyphenyl benzotriazoles, such as TINUVXN* P; mineral fillers, such as mica, talc and CaCO-; dyes, such as NIGROSINE*; flame retardants, such as decabromodiphenyloxide; plasticizers, such as n-alkyl-£-toluene sulfonamide, commercially available as KETJENFLEX*; lubricants, such as polytetrafluoroethylene (PTFE) ; reinforcing aids, such as glass fibers, aramid fibers, stainless steel fibers and carbon fibers; processing aids, such as stearates; and pigments, such as TiO_. Other additives known to those skilled in the art may also be added to the antistatic thermoplastic composition of the present invention. The polyvinyl alcohol (PVA) copolymers useful in the present invention may be prepared in accordance with methods generally known to those skilled in the art. Preferred are copolymers of vinyl acetate and poly(alkyleneoxy)acrylate in which the acetate functionality on the vinyl acetate is then hydrolyzed to yield a vinyl alcohol copolymer. The acetate groups in the polyvinyl alcohol copolymer may be fully hydrolyzed or only partially hydrolyzed, depending on the acid used in the hydrolysis, the hydrolysis reaction time and hydrolysis reaction temperature. Stronger acids, longer reaction times and higher reaction temperatures result in a greater degree of hydrolysis. Preferred polyvinyl alcohol copolymers useful in the present invention are set forth in formula I above and most of these are described in U.S. Patents 4,618,648; 4,675,360, and 4,708,999 of Marten and assigned to Air Products and Chemicals, Inc. Other suitable copolymers are described in U.S. Patent 4,772,663, and European Patent Application Publications 0 275 900 and 0 297 460, also assigned to Air Products and Chemicals, Inc. Commercially available polyvinyl alcohol copolymers useful in the present invention include the VINEX* line of copolymers available from Air Products and Chemicals, Inc. In a preferred embodiment of the present invention, the antistatic thermoplastic composition comprises about 10 to about 30 wt% of the polyvinyl alcohol copolymer. Preferred polyvinyl alcohol copolymer are the VINEX* copolymers available commercially from Air Products and Chemicals, Inc. In another preferred embodiment hygroscopic or water soluble inorganic or organic salts are added to the composition in an effective amount to act as synergists. Such synergist salts may include, for example, Na_C0 3 , ZnCl-, Na-SO., and Sandolec AP (a sodium sulfonate salt of polysulfone) . It is believed that the salt causes moisture to be absorbed by the PVA copolymer, thus resulting in more efficient static dissipation. The amount of salt synergist added to the compositions of the present invention is preferably up to about 5 wt%, and more preferably, about 1 to 2 wt%. Adding greater amounts of salt to the composition may cause some physical degradation of the composition. A preferred polymer/salt synergist combination according to the present invention is polypropylene with Na 2 CO The polyvinyl alcohol copolymer may be combined with the thermoplastic polymer by methods known to those of ordinary skill in the art. Examples of such techniques include mixing the polyvinyl alcohol copolymer with the thermoplastic polymer in a Banbury mixer, melt-blending, extrusion and milling. The final products (e.g., casings or housings for electronic components) may be formed from the thermoplastic compositions of the present invention, for example, by injection molding, coinjection molding, extrusion or coextrusion to films and sheets, and blow molding. While the inventors do not wish to be bound by any particular theory, it is believed that the polyvinyl alcohol copolymers used in the invention absorb water and keep the surface of the thermoplastic wet to dissipate electrostatic charges. Moreover, since the copolymers are of relatively high molecular weight, they are generally not lost from the compositions during use and wear. The invention will now be illustrated in more detail by reference to the following specific, non-limiting examples. In the following examples, antistatic thermoplastic composition samples were compounded on standard processing equipment, namely a 2-1/2 inch diameter Prodex screw extruder, and subsequently injection molded to dimensions of about l/8th inch thick, 3 inches wide and 6 inches long. The samples were then conditioned at 25'C for 24 hours at 15% relative humidity. The following examples relate to the testing of blends of various proportions of the polyvinyl alcohol (PVA) copolymer and a thermoplastic polymer in accordance with the Federal Test Method Standard 101, Method 4046. This test involves the application of an electrical charge to a sample and measuring the time the sample takes to dissipate this charge down to zero volts. The samples were tested according to Method 4046 using a static decay meter device. This device applies about a 5,000- volt charge to the sample and then measures the decay rate. Military specification MIL-B-81705B requires that the charge decay rate from 5,000 volts to zero volts be less than 2 seconds. As is apparent from the data in Table 1, several compositions meet this criterion, i.e., the charge is dissipated even in a low humidity environment. The PVA in all examples was VINEX* 2034 from Air Products and Chemicals, Inc. The polypropylene used in Examples 1A through 3C was maleic anhydride grade polypropylene (i.e. small amounts of maleic anhydride grafted to the polypropylene) , commercially available from Himont, known as PROFAX* SB-222. Example 2 contains sodium carbonate as a salt synergist. Examples 3A through 3C contain 1/8 inch chopped glass fiber from PPG. The ABS used in Examples 4A and 4B was a resin commercially available from Dow Chemical, known as ABS- 340. The polystyrene used in Examples 5A and 5B was a high- impact grade polystyrene, known as FINA* 825, available from American Petrofina, Inc. As can be seen from the above examples, the addition of PVA copolymer according to the invention increases the rate of static decay (dissipation of charge) by a factor of three or more compared to the controls (Examples 1A, 3A, 4A and 5A) which contained no PVA copolymer. The addition of a salt synergist to the compositions of the present invention appears to result in even faster dissipation of charge, as indicated by the static decay results in Example 2 as compared to other examples. The compositions of the present invention unexpectedly maintain their compositional integrity, disperse to substantial homogeneity, and are more economical and easier to process than the compositions of the prior art. In addition, the compositions of the present invention may be colored using suitable pigments well known to those skilled in the art. The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification as indicating the scope of the invention.

Claims: CLAIMS 1. An antistatic thermoplastic mixture comprising about 10 to about 30 wt% of a polyvinyl alcohol copolymer and about 70 to about 90 wt% of a thermoplastic polymer, wherein said thermoplastic polymer is a polymer other than said copolymer. 2. A mixture according to Claim 1 wherein said copolymer is a copolymer of vinyl acetate and poly(alkyleneoxy)- acrylate wherein the acetate functionality is at least partially hydrolyzed to a vinyl alcohol functionality. 3. A mixture according to Claim 2 wherein said acetate functionality is substantially fully hydrolyzed. 4. A mixture according to Claim 1 wherein the polyvinyl alcohol copolymer has the formula: R 1 _f-CH 2 - wherein R is hydrogen, methyl or ethyl; R 2 and R3 are independently hydrogen, alkyl of 1 to about 20 carbons, or aryl of about 6 to 20 carbons; R 4 and R5 are independently hydrogen, alkyl of 1 to about 20 carbons, aryl of about 6 to 20 carbons, or aralkyl of about 7 to 30 carbons; n is 1 to about 1000; x is about 50 to 99.9 mole percent; y is 0 to about 50 mole percent; and z is about 0.001 to 50 mole percent. 5. A mixture according to claim 1 wherein the thermoplastic polymer is selected from the group consisting of styrenics, halogenated polymers, polyesters, polyolefins, polycarbonates, polyamides, polyurethanes, .ABS copolymers, SAN copolymers, rubbers, polysulfones, and fluoropolymers. 6. A mixture according to claim 1 further comprising an additive selected from the group consisting of glass fibers, carbon fibers, ara id fibers, stainless steel fibers, mineral fillers and flame retardants. 7. A mixture according to claim 1 further comprising a hygroscopic or water soluble inorganic or organic salt in an amount effective to act as an antistatic synergist for said copolymer. 8. A mixture according to claim 7 wherein said polymer is polypropylene and said salt is sodium bicarbonate. 9. A mixture according to claim 1 further comprising a pigment to color said composition. 10. A mixture according to claim 1 wherein said polymer is polypropylene and the composition further comprises about 10 weight percent glass fibers as a reinforcing aid. 11. A method of improving the antistatic properties of a thermoplastic polymer comprising adding to the polymer about 10 to about 30 wt% of a polyvinyl alcohol copolymer, wherein said thermoplastic polymer is a polymer other than said copolymer. 12. A method according to claim 11 wherein said copolymer is a copolymer of vinyl acetate and poly(aklyleneoxy) acrylate wherein the acetate functionality is at least partially hydrolyzed to a vinyl alcohol functionality. 13. A method according to claim 11 wherein a hygroscopic or water soluble inorganic or organic salt is added to the polymer in an amount effective to act as an antistatic synergist for said copolymer. 14. An antistatic thermoplastic mixture comprising about 5 to about 50 wt% of a polyvinyl alcohol copolymer and about 50 to about 95 wt% of a thermoplastic polymer, wherein said copolymer is a copolymer of vinyl acetate and poly(alkyleneoxy)acrylate wherein the acetate functionality is at least partially hydrolyzed to a vinyl alcohol functionality and said thermoplastic polymer is a polymer other than said copolymer. 15. A composition according to claim 14 wherein said acetate functionality is substantially fully hydrolyzed. 16. A composition according to claim 14 wherein the polyvinyl alcohol copolymer has the formula: ■CH 2Λ -- wherein R is hydrogen, methyl or ethyl; R 2 and R3 are independently hydrogen, alkyl of 1 to about 20 carbons, or aryl of about 6 to 20 carbons; R4 and R5 are independently hydrogen, alkyl of 1 to about 20 carbons, aryl of about 6 to 20 carbons, or aralkyl of about 7 to 30 carbons; n is 1 to about 1000; x is about 50 to 99.9 mole percent; y is 0 to about 50 mole percent; and z is about 0.001 to 50 mole percent. 17. A composition according to claim 14 wherein the thermoplastic polymer is selected from the group consisting of styrenics, halogenated polymers, polyesters, polyolefins, polycarbonates, polyamides, polyurethanes, ABS copolymers, SAN copolymers, polysulfones , and fluoropolymers. 18. A composition according to claim 14 further comprising an additive selected from the group consisting of glass fibers, carbon fibers, aramid fibers, stainless steel fibers, mineral fillers and flame retardants. 19. A composition according to claim 14 further comprising a hygroscopic or water soluble inorganic or organic salt in an amount effective to act as an antistatic synergist for said copolymer. 20. A composition according to claim 19 wherein said polymer is polypropylene and said salt is sodium carbonate. 21. A composition according to claim 14 further comprising a pigment to color said composition. 22. A composition according to claim 14 wherein said polymer is polypropylene and the composition further comprises about 10 weight percent glass fibers as a reinforcing aid. 23. A method of improving the antistatic properties of a thermoplastic polymer comprising adding to the polymer about 5 to about 50 wt% of a polyvinyl alcohol copolymer, wherein said copolymer is a copolymer of vinyl acetate and poly(alkyleneoxy)acrylate wherein the acetate functionality is at least partially hydrolyzed to a vinyl alcohol functionality and said thermoplastic polymer is a polymer other than said copolymer. 24. A method according to claim 23 wherein a hygroscopic or water soluble inorganic or organic salt is added to the polymer in an amount effective to act as an antistatic synergist for said copolymer.

Inventors: BOLVARI ANNE, WARD SUSAN K, BOLVARI, ANNE, WARD, SUSAN, K.
Applicants: KAWASAKI STEEL PLASTICS INC, KAWASAKI STEEL PLASTICS INC.
Application year: 1992
Main classification: C08L101
IPC codes: C08F8, C08F20, C08F220, C08K3, C08K7, C08L23, C08L25, C08L51, C08L101