FLAME RETARDANT POLYMER COMPOSITIONS

• US 20130331478A1
• Filed: 05/24/2013
• Published: 12/12/2013
• Est. Priority Date: 05/24/2012
• Status: Active Grant

• Current Assignee: SHPP Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Inventors: La Camera, Domenico, Kormelink, Hendrik, Bozovic-Vukic, Jelena, Prez, Yohana
• Granted Patent: US 9,006,306 B2
• Time in Patent Office: Days
• US Class Current: 522/174
• CPC Class Codes: C08K 5/0025 Crosslinking or vulcanising agents; including accelerators
• CPC Class Codes: C08K 5/5313 Phosphinic compounds, e.g. R2=P(:O)OR'
• CPC Class Codes: C08L 67/00 Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain of polyester-amides C08L77/12; of polyester-imides C08L79/08; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 77/00 Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain of polyhydrazides C08L79/06; of polyamideimides or polyamide acids C08L79/08; Compositions of derivatives of such polymers

Abstract

In one aspect, the invention relates to crosslinkable, flame retardant polymer compositions are provided comprising a polyamide or polyester; a flame retardant system; a crosslinking agent; and a flame retardant system coagent. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present invention.

Claims

1. A flame retardant composition, comprising:

(a) a polyamide or polyester;

(b) a crosslinking agent,

(c) a flame retardant system comprising a metal phosphinate salt, a metal diphosphinate salt, or combination thereof; and

(d) a flame retardant system coagent;

wherein the crosslinking agent comprises two or more groups capable of forming free radicals under beta or gamma radiation.

2. The composition of claim 1, wherein the metal phosphinate salt is of the formula (I) and the metal diphosphinate salt is of the formula (II)

3. The composition of claim 1, wherein the metal salt is an aluminum salt of dimethylphosphinic acid, an aluminum salt of methylethylphosphinic acid, or an aluminum salt of methylpropylphosphinic acid.

4. The composition of claim 1, wherein the flame retardant system further comprises at least one nitrogen compound selected from the group consisting of condensation products of melamine and/or reaction products of condensation products of melamine with phosphoric acid, and/or mixtures thereof, melam, melem, melon, melamine, melamine cyanurate, melamine phosphate compounds, dimelamine phosphate, melamine pyrophosphate, melamine polyphosphate compounds, benzoguanamine compounds, terephthalic ester compounds of tris(hydroxyethyl)isocyanurate, allantoin compounds, glycoluril compounds, ammeline, ammelide, and combinations thereof.

5. The composition of claim 4, wherein the nitrogen compound comprises a compound of the formula (III) to (VIII) or combinations comprising at least one of the foregoing nitrogen compounds

6. The composition of claim 4, wherein the nitrogen compound is allantoin, benzoguanaine, glycoluril, melamine, melamine cyanurate, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, or urea cyanurate.

7. The composition of claim 1, wherein the polyamide is selected from the group consisting of nylon-6, nylon-6,6, nylon-4, nylon-4,6, nylon-12, nylon-6,10, nylon-6,9, nylon-6,12, nylon-9T, copolymer of nylon-6,6 and nylon-6, polyamide copolymers, polyamide blends, and combinations thereof.

8. The composition of claim 1, wherein the polyamide or polyester is present in an amount of about 20 to about 96 wt % based on the total weight of the composition.

9. The composition of claim 1, wherein the polyester is derived from an aliphatic diol and an aromatic dicarboxylic acid having repeating units of the following general formula:

10. The composition of claim 1, wherein the polyester is poly(ethylene terephthalate), poly(1,4-butylene terephthalate), poly(ethylene naphthanoate), poly(butylene naphthanoate), poly(propylene terephthalate), or a combination thereof.

11. The composition of claim 1, wherein the crosslinking agent comprises two or more unsaturated groups.

12. The composition of claim 1, wherein the crosslinking agent is a polyallylic compound or a polyol poly(meth)acrylate prepared from an aliphatic diol, triol, or tetraol containing 2-100 carbon atoms.

13. The composition of claim 1, further comprising up to about 60 wt % of filler.

14. The composition of claim 1, wherein the filler is glass fiber, zinc borate, or a combination thereof.

15. The composition of claim 1, further comprising up to about 20 wt % of a wear additive based on the total weight of the composition, wherein the wear additive is selected from the group consisting of polytetrafluoroethylene, molybdenum disulfide, graphite, aramide, carbon fiber, carbon powder, and combinations thereof.

16. The composition of claim 1, wherein the composition is crosslinked with ionizing radiation to form a crosslinked composition.

17. The composition of claim 1, wherein the composition after crosslinking exhibits at least one of the following:

(a) a Glow Wire Flammability Index as measured according to IEC-60695-2-1 of 960°

C., or greater within the range of 0.8 to 3.2 millimeters thickness;

(b) a Glow Wire Ignition Temperature as measured according to IEC-60695-2-13 of 750°

C., or greater within the range of 0.8 to 3.2 millimeters thickness;

or

(c) a comparative tracking index measured according to International Electrotechnical Commission standard IEC-60112/3^rd of class 1 or class 0.

18. The composition of claim 1, wherein the flame retardant system co-agent comprises boehmite.

19. The composition of claim 1, wherein the flame retardant system co-agent is present in an amount of about 1 to about 50 wt % of the total weight of the composition.

20. The composition of claim 1, wherein the flame retardant system co-agent comprises a mineral flame retardant, an aromatic polymer, a phosphorous flame retardant, or a combination thereof.

21. The composition of claim 20, wherein the aromatic polymer is selected from polyphenyl ether, polyetherimide, polyamideimide, polyetherimide/polyimide copolymers, polyarylene sulfide, polysulphone, polyethersulphone, polyetherketone, or a combination thereof.

22. The composition of claim 21, wherein the polyphenyl ether is poly(arylene ether).

23. The composition of claim 20, wherein the mineral flame retardant is selected from a metal hydroxide, a hydroxycarbonate, a borate, an oxide mineral, or a combination thereof.

24. The composition of claim 20, wherein the mineral flame retardant is selected from aluminum tri-hydroxide, aluminum oxide hydroxide, magnesium di-hydroxide, or a combination including at least one of the foregoing flame retardants.

25. The composition of claim 20, wherein the phosphorus flame retardant is selected from a polyphosphonate, a polyphosphonate-polycarbonate copolymer, a phosphazene compound, an aryl phosphate, a sulphonate salt, or a combination thereof.

26. The composition of claim 25, wherein the aryl phosphate is selected from resorcinol diphenyl phosphate, bisphenol A diphenyl phosphate, or a combination thereof.

27. The composition of claim 25, wherein the phosphorus flame retardant comprises a polyphosphonate.

28. The composition of claim 27, wherein the polyphosphonate comprises residues derived from diphenyl-methyl-phosphonate (DPP).

29. The composition of claim 28, wherein the polyphosphonate comprises is a homopolymer comprising residues derived from diphenyl-methyl-phosphonate (DPP).

30. The composition of claim 25, wherein the sulphonate salt is potassium diphenyl sulphone sulphonate, potassium perfluorobutane sulfonate, or a combination thereof.

31. The composition of claim 25, wherein the phosphazene compound comprises a phenoxycyclophosphazene.

32. The composition of claim 1, wherein the flame retardant composition produces a reduced level of acidic species when compared to a corresponding or reference composition in the absence of the flame retardant system co-agent and reduction in the flame retardant system, produced under substantially identical compounding and molding conditions.

33. The composition of claim 1, wherein the flame retardant composition substantially prevents or inhibits corrosion when compared to a corresponding or reference composition in the absence of the flame retardant system co-agent and reduction in the flame retardant system, produced under substantially identical compounding and molding conditions.

34. An article comprising the crosslinked composition of claim 16.

35. A flame retardant composition, comprising:

(a) a polyamide or polyester;

(b) about 1 to about 20 wt % of a polyallylic compound or a polyol poly(meth)acrylate crosslinking agent;

(c) about 5 to about 60 wt % of glass fiber;

(d) about 5 to about 25 wt % of a flame retardant system comprising

i. a metal phosphinate salt, a metal diphosphinate salt, or a combination thereof; and

ii. optionally at least one nitrogen compound selected from the group consisting of condensation products of melamine and/or reaction products of condensation products of melamine with phosphoric acid, and/or mixtures thereof, melam, melem, melon, melamine cyanurate, melamine phosphate compounds, dimelamine phosphate, melamine pyrophosphate, benzoguanamine compounds, terepthalic ester compounds of tris(hydroxyethyl)isocyanurate, allantoin compounds, glycoluril compounds, ammeline, ammelide, and combinations thereof; and

(e) about 1 to 15 wt % of a flame retardant system coagent;

wherein all the amounts are based upon the total weight of the composition.

36. The composition of claim 35, wherein the polyamide comprises about 15 to about 35 wt % nylon-6 and about 15 to about 35 wt % nylon-6,6;

(a) about 1 to about 10 wt % of a crosslinking agent selected from the group consisting of triallylisocyanurate, triallylcyanurate, ethyleneglycol di(meth)acrylate, and trimethylolpropane tri(meth)acrylate;

(b) about 15 to about 30 wt % of glass fiber; and

(c) about 10 to about 20 wt % of the flame retardant system wherein the nitrogen compound is melamine, melamine phosphate, melamine pyrophosphate, or melamine polyphosphate;

wherein all the amounts are based upon the total weight of the composition.

37. A method of forming a crosslinkable, flame retardant composition comprising:

(a) blending a polyamide, a crosslinking agent, wherein the crosslinking agent comprises two or more groups capable of forming free radicals under beta or gamma radiation;

(b) a flame retardant system coagent, and

(c) a flame retardant system comprising

i. a metal phosphinate salt, a metal diphosphinate salt, or combination thereof; and

ii. optionally at least one nitrogen compound selected from the group consisting of condensation products of melamine and/or reaction products of condensation products of melamine with phosphoric acid, and/or mixtures thereof, melam, melem, melon, melamine, melamine cyanurate, melamine phosphate compounds, dimelamine phosphate, melamine pyrophosphate, melamine polyphosphate compounds, benzoguanamine compounds, terepthalic ester compounds of tris(hydroxyethyl)isocyanurate, allantoin compounds, glycoluril compounds, ammeline, ammelide, and combinations thereof, to form an intimate blend.

38. The method of claim 37, further comprising molding the intimate blend into an article and crosslinking the composition with ionizing radiation.