Phosphorus-containing flame retardant agglomerates

• US 20050143503A1
• Filed: 10/06/2004
• Published: 06/30/2005
• Est. Priority Date: 10/07/2003
• Status: Active Grant

• Current Assignee: Clariant Produkte AG (Clariant AG)
• Original Assignee: Clariant GmbH (Clariant AG)
• Inventors: Hoerold, Sebastian, Bauer, Harald, Krause, Werner, Sicken, Martin
• Granted Patent: US 7,259,200 B2
• Time in Patent Office: Days
• US Class Current: 524/115
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08J 2377/02 Polyamides derived from omega-amino carboxylic acids or from lactams thereof C08J2377/10 takes precedence
• CPC Class Codes: C08J 2377/06 Polyamides derived from polyamines and polycarboxylic acids C08J2377/10 takes precedence
• CPC Class Codes: C08J 3/223 Packed additives
• CPC Class Codes: C08K 5/0066 Flame-proofing or flame-retarding additives
• CPC Class Codes: C08K 5/5313 Phosphinic compounds, e.g. R2=P(:O)OR'

Abstract

The invention relates to phosphorus-containing flame retardant agglomerates comprising
a) from 99.99 to 80% by weight of aggregates and/or primary particles composed of a phosphinic salt of the formula (I) and/or composed of a diphosphinic salt of the formula (II), and/or composed of polymers of these, where

• • R¹,R² are identical or different and are C₁-C₆-alkyl, linear or branched, and/or aryl;
  • R³ is C₁-C₁₀-alkylene, linear or branched, C₆-C₁₀-arylene, -alkylarylene or -arylalkylene; M is Mg, Ca, Al, Sb, Sn, Ge, Ti, Fe, Zr, Ce, Bi, Sr, Mn, Li, Na, K and/or a protonated nitrogen base;
  • m is from 1 to 4; n is from 1 to 4; x is from 1 to 4 and
  • b) from 0.01 to 20% by weight of auxiliaries. The invention likewise relates to a process for the production of these phosphorus-containing flame retardant agglomerates, and also to polymeric compositions and moldings which comprise these phosphorus-containing flame retardant agglomerates.

Claims

1. A phosphorus-containing flame retardant agglomerate, comprising

a) from 99.99 to 80% by weight of aggregates and/or primary particles comprising at least one phosphinic compound selected from the group consisting of a phosphinic salt of the formula (I), a diphosphinic salt of the formula (II), a polymer of the phosphinic salt, a polymer of the diphosphinic salt and mixtures thereof,

where

R¹,R² are identical or different and are C₁-C₆-alkyl, linear or branched, or aryl;

R³ is C₁-C₁₀-alkylene, linear or branched, C₆-C₁₀-arylene, -alkylarylene or -arylalkylene;

M is Mg, Ca, Al, Sb, Sn, Ge, Ti, Fe, Zr, Ce, Bi, Sr, Mn, Li, Na, K or a protonated nitrogen base;

m is from 1 to 4;

n is from 1 to 4;

x is from 1 to 4 and

b) from 0.01 to 20% by weight of aggregates and/or primary particles of at least one auxiliary, wherein the at least one auxiliary is a polymer or copolymer based on vinylpyrrolidone, vinyl acetate, or vinylcaprolactam, epoxides, urethanes, acrylates, esters, amides, stearates, olefins, cellulose derivatives, or a mixture thereof.

2. The phosphorus-containing flame retardant agglomerates as claimed in claim 1

wherein the aggregates and/or primary particles further comprises at least one synergist.

3. The phosphorus-containing flame retardant agglomerate as claimed in claim 2, wherein component a) comprises from 30 to 99.9% by weight of the at least one phosphinic compound, and

from 0.1 to 70% by weight of the at least one synergist.

4. The phosphorus-containing flame retardant agglomerate as claimed in claim 2, wherein component a) comprises

from 50 to 99% by weight of a zinc, aluminum, titanium, zirconium or iron salt of the phosphinic acid of the formula (I), of the diphosphinic acid of the formula (II) polymers thereof and mixtures thereof, and

from 1 to 50% by weight of the at least one synergist selected from the group consisting of the salts of phosphoric acid and their condensates, salts of cyanuric acid with melamine and its condensates and hydrolysis products thereof.

5. The phosphorus-containing flame retardant agglomerate as claimed in claim 4, wherein the at least one synergist is a zinc compound.

6. The phosphorus-containing flame retardant agglomerate as claimed in claim 2, wherein the at least one synergist is selected from the group consisting of nitrogen compounds, phosphorus compounds, and phosphorus and nitrogen compounds.

7. The phosphorus-containing flame retardant agglomerate as claimed in claim 2, wherein the at least one synergist is a nitrogen compound of the formulae (III) to (VIII), or a mixture thereof

8. The phosphorus-containing flame retardant agglomerate as claimed in claim 2, wherein the at least one synergist is a synthetic inorganic compound or a mineral product.

9. The phosphorus-containing flame retardant agglomerate as claimed in claim 8, wherein the at least one synergist is selected from the group consisting of oxygen compounds of silicon, magnesium compounds, metal carbonates of metals of the second main group of the Periodic Table, red phosphorus, compounds of zinc or of aluminum, and antimony.

10. The phosphorus-containing flame retardant agglomerate as claimed in claim 5, wherein the zinc compound is selected from the group consisting of zinc oxide, zinc hydroxide, zinc oxide hydrate, anhydrous zinc carbonate, basic zinc carbonate, zinc hydroxide carbonate, basic zinc carbonate hydrate, basic zinc silicate, zinc hexafluorosilicate, zinc stannate, zinc magnesium aluminum hydroxide carbonate, zinc hexafluorosilicate hexahydrate, zinc salts of the oxo acids of the third main group, zinc salts of the oxo acids of the fifth main group, zinc salts of the oxo acids of the transition metals, zinc chromite, zinc molybdate, zinc permanganate, and zinc molybdate magnesium silicate.

11. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, wherein the melting or softening point of the at least one auxiliary is from 40 to 350°

C.

12. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, wherein the at least one auxiliary is selected from the group consisting of polyvinyl alcohol, polyvinyl butyral (PVB), polyvinylcaprolactam, hydroxyethylcellulose, hydroxypropylcellulose, and sodium carboxymethylcellulose.

13. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, whose median particle size is from 0.1 to 3000 μ

m.

14. A process for preparing a phosphorus-containing flame retardant agglomerate as claimed in claim 1, comprising the step of agglomerating the aggregates and/or primary particles of the at least one phosphinic compound in the presence of the aggregates and/or primary particles of the at least one auxiliary in a mixer, or a fluidized bed, or via spray drying.

15. The process as claimed in claim 14, wherein the agglomerating step further comprises mixing the aggregates and/or primary particles of the at least one phosphinic compound, the aggregates and/or primary particles of the at least one auxiliary, in a solvent to form a mixture, feeding the mixture to a fluidized bed, drying the mixture, granulating the mixture to form the agglomerates, isolating the agglomerates and separating the agglomerates having a predetermined grain size.

16. The process as claimed in claim 14, wherein the agglomerating step further comprises feeding the aggregates and/or primary particles of the at least one phosphinic compound, the aggregates and/or primary particles of the at least one auxiliary into a fluidized bed, metering in a solvent to the fluidized bed to form a mixture, granulating the mixture to form the agglomerates, isolating the agglomerates, and separating the agglomerates having a predetermined grain size.

17. The process as claimed in claim 15, wherein the agglomerating step further comprises returning agglomerates having a grain size greater than or less than the predetermined grain size for further processing.

18. The process as claimed in claim 14, wherein the solvent is selected from the group consisting of water, alcohols, glycols, aromatics, aliphatics, cycloaliphatics, ethers, glycol ethers, ketones, esters, chlorinated hydrocarbons and aromatics, and mixtures thereof.

19. The process as claimed in claim 14, wherein the agglomerating step occurs in one or more stages at a pressure of from 10 to 100 000 000 Pa, for a period of from 0.01 to 1000 h, and at a temperature of from −

20 to +500°

C.

20. A flame-retardant polymer molding composition, comprising

from 1 to 50% by weight of phosphorus-containing flame retardant agglomerates as claimed in claim 1,

from 1 to 99% by weight of thermoplastic polymer or a mixture thereof,

from 0 to 60% by weight of additives, and

from 0 to 60% by weight of filler.

21. The flame-retardant polymer molding composition as claimed in claim 20, wherein the thermoplastic polymer is selected from the group consisting HI (high-impact) polystyrene, polyphenylene ether, polyamides, polyesters, polycarbonates, and blends or polyblends of the type represented by ABS (acrylonitrile-butadiene-styrene) and PC/ABS (polycarbonate/acrylonitrile-butadiene-styrene).

22. A polymeric article comprising phosphorus-containing flame retardant agglomerates as claimed in claim 1.

23. A flame-retardant coating comprising

from 1 to 50% by weight of phosphorus-containing flame retardant agglomerates as claimed in claim 1,

from 0 to 60% by weight of ammonium polyphosphate, and

from 0 to 60% by weight of additives and auxilaries.

24. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, wherein the melting or softening point of the at least one auxiliary is from 60 to 300°

C.

25. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, wherein the median particle size is from 100 to 3000 μ

m.

26. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, wherein the median particle size is from 200 to 2000 μ

m.

27. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, having a bulk density of from 80 to 800 g/l.

28. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, having a bulk density of from 200 to 500 g/l.

29. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, having a bulk density of from 200 to 400 g/l.

30. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, wherein the median particle diameter of the aggregates of the at least one phosphinic compound or the at least one synergist is from 0.1 to 500 μ

m.

31. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, wherein the median particle diameter of the aggregates of the at least one phosphinic compound or the at least one synergist is from 1 to 100 μ

m.

32. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, wherein the median particle diameter of the primary particles of the at least one phosphinic compound or the at least one synergist is from 0.1 to 50 μ

m.

33. The phosphorus-containing flame retardant agglomerate as claimed in claim 1, wherein the median particle diameter of the primary particles of the at least one phosphinic compound or the at least one synergist is from 1 to 10 μ

m.

34. The process as claimed in claim 16, wherein the agglomerating step further comprises returning agglomerates having a grain size greater than or less than the predetermined grain size for further processing.

35. The process as claimed in claim 14, wherein the temperature is from 50 to 350°

C.

36. The polymeric article as claimed in claim 22, wherein the polymeric article is a polymeric molding, film or fiber.

37. An article coated with the flame retardant coating as claimed in claim 23.

38. A process for preparing a phosphorus-containing flame retardant agglomerate as claimed in claim 2, comprising the step of agglomerating the aggregates and/or primary particles of the at least one phosphinic compound and the at least one synergist in the presence of the aggregates and/or primary particles of the at least one auxiliary in a mixer, or a fluidized bed, or via spray drying.