Flame retardant polyester compositions for calendering
First Claim
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1. A flame retardant polyester composition for calendering, comprising:
- (a) a polyester having a crystallization half time from a molten state of at least 5 minutes wherein said polyester is a random copolymer;
(b) about 10 to about 40 wt % of a plasticizer capable of dissolving a 5-mil (0.127 mm) thick film of said polyester to produce a clear solution at a temperature of 23°
C. to 160°
C.;
(c) a phosphorus-containing flame retardant miscible with said polyester plasticized with said plasticizer; and
(d) an additive effective to prevent sticking of the polyester to calendering rolls.
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Abstract
Flame retardant polyester compositions suitable for calendering may be prepared from polyesters having crystallization half time of at least 5 minutes, a plasticizer, a phosphorus-containing flame retardant miscible with the plasticized polyester, and an additive effective to prevent sticking of the polyester to the calendar rolls. Also disclosed are processes for flame retardant films or sheets by calendering the above compositions and the flame retardant films or sheets produced therefrom. These films and sheets have excellent appearance, flexibility, and flame retardancy, and can be used in a wide range of decorative and packaging applications.
85 Citations
101 Claims
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1. A flame retardant polyester composition for calendering, comprising:
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(a) a polyester having a crystallization half time from a molten state of at least 5 minutes wherein said polyester is a random copolymer; (b) about 10 to about 40 wt % of a plasticizer capable of dissolving a 5-mil (0.127 mm) thick film of said polyester to produce a clear solution at a temperature of 23°
C. to 160°
C.;(c) a phosphorus-containing flame retardant miscible with said polyester plasticized with said plasticizer; and (d) an additive effective to prevent sticking of the polyester to calendering rolls. - View Dependent Claims (2, 3)
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4. The polyester composition of 3 wherein said plasticizer is an ester comprising
(i) an acid residue comprising one or more of: - phthalic acid, adipic acid, trimellitic acid, benzoic acid, azelaic acid, terephthalic acid, isophthalic acid, butyric acid, glutaric acid, citric acid or phosphoric acid; and
(ii) an alcohol residue comprising one or more aliphatic, cycloaliphatic, or aromatic alcohols containing up to about 20 carbon atoms. - View Dependent Claims (5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
- phthalic acid, adipic acid, trimellitic acid, benzoic acid, azelaic acid, terephthalic acid, isophthalic acid, butyric acid, glutaric acid, citric acid or phosphoric acid; and
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20. A flame retardant polyester composition for calendering, comprising:
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(a) a polyester having a crystallization half time from a molten state of at least 10 minutes wherein said polyester is a random copolymer comprising (i) at least 80 mole percent of diacid residues comprising one or more of;
terephthalic acid, naphthalenedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, or isophthalic acid; and
(ii) diol residues comprising about 20 to about 40 mole percent 1,4-cyclohexanedimethanol and about 60 to about 80 mole percent of one or more diols containing 2 to about 20 carbon atoms, wherein said diacid residues are based on 100 mole percent and the diol residues are based on 100 mole percent;(b) about 10 wt % to about 40 wt % of a plasticizer comprising one or more benzoates, phthalates, phosphates, or isophthalates, wherein said plasticizer is capable of dissolving a 5-mil (0.127 mm) thick film of said polyester to produce a clear solution at a temperature of 23°
C. to 160°
C.;(c) about 5 wt % to about 40 wt % of a phosphorus-containing flame retardant miscible with said polyester plasticized with said plasticizer; and (d) an additive effective to prevent sticking of the polyester to calendering rolls, wherein said wt % is based upon the total weight of said polyester composition. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A process for preparing a flame retardant film or a sheet, comprising:
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calendering a polyester composition comprising (a) a polyester having a crystallization half time from a molten state of at least 5 minutes, wherein said polyester is a random copolymer; (b) about 10 to about 40 wt % of a plasticizer capable of dissolving a 5-mil (0.127 mm) thick film of said polyester to produce a clear solution at a temperature of 23°
C. to 160°
C.;(c) a phosphorus-containing flame retardant miscible with said polyester plasticized with said plasticizer; and (d) an additive effective to prevent sticking of the polyester to calendering rolls. - View Dependent Claims (32, 33)
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34. The process of 33 wherein said plasticizer is an ester comprising
(i) an acid residue comprising one or more of: - phthalic acid, adipic acid, benzoic acid, azelaic acid, terephthalic acid, isophthalic acid, butyric acid, glutaric acid, or phosphoric acid; and
(ii) an alcohol residue comprising one or more of;
methanol, ethanol, propanol, isopropanol, butanol, isobutanol, stearyl alcohol, lauryl alcohol, phenol, benzyl alcohol, hydroquinone, catechol, resorcinol, ethylene glycol, neopentyl glycol, 1,4-cyclohexanedimethanol, or diethylene glycol. - View Dependent Claims (35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47)
- phthalic acid, adipic acid, benzoic acid, azelaic acid, terephthalic acid, isophthalic acid, butyric acid, glutaric acid, or phosphoric acid; and
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48. A flame retardant film or sheet comprising a polyester composition, said polyester composition comprising
(a) a polyester having a crystallization half time from a molten state of at least 5 minutes, wherein said polyester is a random copolymer; -
(b) about 10 to about 40 wt % of a plasticizer capable of dissolving a 5-mil (0.127 mm) thick film of said polyester to produce a clear solution at a temperature of 23°
C. to 160°
C.;(c) an phosphorus-containing flame retardant miscible with said polyester plasticized with said plasticizer; and (d) an additive effective to prevent sticking of the polyester to calendering rolls, wherein said film or sheet is prepared by calendering said polyester composition. - View Dependent Claims (49, 50)
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51. The film or sheet of 50 wherein said plasticizer is an ester comprising
(i) an acid residue comprising one or more of: - phthalic acid, adipic acid, benzoic acid, azelaic acid, terephthalic acid, isophthalic acid, butyric acid, glutaric acid, or phosphoric acid; and
(ii) an alcohol residue comprising one or more of;
methanol, ethanol, propanol, isopropanol, butanol, isobutanol, stearyl alcohol, lauryl alcohol, phenol, benzyl alcohol, hydroquinone, catechol, resorcinol, ethylene glycol, neopentyl glycol, 1,4-cyclohexanedimethanol, or diethylene glycol. - View Dependent Claims (52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63)
- phthalic acid, adipic acid, benzoic acid, azelaic acid, terephthalic acid, isophthalic acid, butyric acid, glutaric acid, or phosphoric acid; and
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64. A flame retardant polyester composition for calendering, comprising:
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(a) about 50 to about 95 weight percent of a polyester having a melting temperature of less than 220°
C. and exhibiting more than 1 percent crystallinity after annealing for 2000 minutes at a temperature at which said polyester has a maximum crystallization rate, wherein said polyester is a random copolymer;(b) about 10 to about 40 wt % of a plasticizer capable of dissolving a 5-mil (0.127 mm) thick film of said polyester to produce a clear solution at a temperature of 23°
C. to 160°
C.; and(c) a phosphorus-containing flame retardant miscible with said polyester plasticized with said plasticizer. - View Dependent Claims (65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76)
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77. A process for preparing a flame retardant film or a sheet, comprising:
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(i) calendering a polyester composition comprising (a) about 50 to about 95 weight percent of a polyester having a melting temperature of less than 220°
C. and exhibiting more than 1 percent crystallinity after annealing for 2000 minutes at a temperature at which said polyester has a maximum crystallization rate, wherein said polyester is a random copolymer;(b) about 10 to about 40 wt % of a plasticizer capable of dissolving a 5-mil (0.127 mm) thick film of said polyester to produce a clear solution at a temperature of 23°
C. to 160°
C.; and(c) a phosphorus-containing flame retardant miscible with said polyester plasticized with said plasticizer; and (ii) inducing crystallization during step (i) or after step (i). - View Dependent Claims (78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89)
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90. A flame retardant film or sheet, comprising;
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(a) about 50 to about 95 weight percent of a polyester having a melting temperature of less than 220°
C. and exhibiting more than 1 percent crystallinity after annealing for 2000 minutes at a temperature at which said polyester has a maximum crystallization rate, wherein said polyester is a random copolymer;(b) about 10 to about 40 weight percent of a plasticizer capable of dissolving a 5-mil (0.127 mm) thick film of said polyester to produce a clear solution at a temperature of 23°
C. to 160°
C.; and(c) a phosphorus-containing flame retardant miscible with said polyester plasticized with said plasticizer. - View Dependent Claims (91, 92)
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93. The film or sheet of 92 wherein said plasticizer is an ester comprising
(i) an acid residue comprising one or more of: - phthalic acid, adipic acid, benzoic acid, azelaic acid, terephthalic acid, isophthalic acid, butyric acid, glutaric acid, or phosphoric acid; and
(ii) an alcohol residue comprising one or more of methanol, ethanol, propanol, isopropanol, butanol, isobutanol, stearyl alcohol, lauryl alcohol, phenol, benzyl alcohol, hydroquinone, catechol, resorcinol, ethylene glycol, neopentyl glycol, 1,4-cyclohexanedimethanol, or diethylene glycol. - View Dependent Claims (94, 95, 96, 97, 98, 99, 100, 101)
- phthalic acid, adipic acid, benzoic acid, azelaic acid, terephthalic acid, isophthalic acid, butyric acid, glutaric acid, or phosphoric acid; and
Specification