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WO2000012608A1 - Flame resistant polyketone resin compositions - Google Patents

Flame resistant polyketone resin compositions Download PDF

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Publication number
WO2000012608A1
WO2000012608A1 PCT/US1999/017224 US9917224W WO0012608A1 WO 2000012608 A1 WO2000012608 A1 WO 2000012608A1 US 9917224 W US9917224 W US 9917224W WO 0012608 A1 WO0012608 A1 WO 0012608A1
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Prior art keywords
composition
weight
parts
flame retardant
phosphorous
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French (fr)
Inventor
Johannes Cornelis Gosens
Gerrit De Wit (Gert)
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General Electric Co
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General Electric Co
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Priority claimed from US09/144,687 external-priority patent/US5973041A/en
Application filed by General Electric Co filed Critical General Electric Co
Priority to AU52419/99A priority Critical patent/AU5241999A/en
Publication of WO2000012608A1 publication Critical patent/WO2000012608A1/en
Anticipated expiration legal-status Critical
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/49Phosphorus-containing compounds
    • C08K5/5399Phosphorus bound to nitrogen
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/03Use of materials for the substrate
    • H05K1/0313Organic insulating material
    • H05K1/0353Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement
    • H05K1/0373Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement containing additives, e.g. fillers

Definitions

  • Polymer compositions comprising polymers of carbon monoxide and at least one olefin are generally known in the art. Of particular interest in such compositions are polymer components comprising linear alternating polymers of carbon monoxide and one or more olefins, hereafter referred to as polyketones.
  • Polymer compositions comprising a polyketone polymers and flame retardant additives are also known in the art and have been described, for example, in U.S. Patents U.S. 4,761,449; U.S. 4,885,318; U.S. 4,885,328; U.S. 4,921,897; U.S. 5,030,674 and U.S. 5,633,301.
  • U.S. Patent 5,030,674 discloses the use of a combination of a cyclic phosphonate ester and a polytetrafluoroethylene resin as flame retardant additives in polyketone polymer compositions.
  • U.S. Patents U.S. 4,761,449; U.S. 4,885,318; U.S. 4,885,328; U.S. 4,921,897; U.S. 5,030,674 and U.S. 5,633,301.
  • U.S. Patent 5,030,674 discloses the use of a combination of a cyclic
  • Patent 5,633,301 discloses the use of a combination of a bicyclic phosphorous compound, e.g., bis(pentaerythritol phosphate alcohol) carbonate and an intumescent flame retardant compound containing nitrogen and phosphorous, e.g., melamine phosphate, as flame retardant additives in polyketone polymer compositions.
  • the composition may also optionally include an aryl group-containing monophosphate ester compound, e.g., triphenyl phosphate, which is said to enhance the processability of the composition.
  • Polyketone polymer compositions can also be made flame retardant by the inclusion of halogenated organic flame retardants and/or by inclusion of inorganic metal oxides, hydroxides and carbonates in the polymer composition.
  • Halogenated organic compounds generate toxic halogen gases 5 when subjected to burning and it is thus environmentally desirable to avoid the use of these materials, particularly at the higher levels of addition needed to achieve flame retardant properties.
  • Inorganic metal compounds tend to increase the density of the polyketone polymer composition and their use at higher levels tends to markedly affect the physical, mechanical and melt l o stability of the polymer composition.
  • the present invention provides new compositions having flame retardant properties which are more friendly to the environment and which possess good physical and mechanical properties.
  • This invention relates to flame retardant polyketone polymer
  • At least one phosphorous-containing flame retardant 20 parts by weight of at least one phosphorous-containing flame retardant; c) 0 to 30 parts by weight of at least one supplemental flame retardant selected from the group consisting of metal borates, metal hydroxides, metal oxides and metal carbonates; d) 0 to 40 parts by weight of at least one reinforcing filler; and e) 0 to 5 parts by weight of at least one anti-dripping agent which
  • compositions in accordance with this invention exhibit good flame retardant properties while maintaining a good balance in mechanical
  • polymers used in the polymer compositions of the invention are meant to include all polymers containing units derived from carbon monoxide and units derived from one or more olefins.
  • This definition includes both random polymers produced by radical polymerization and linear alternating polymers, hereafter all referred to as polyketones. Suitable polyketones and processes for their preparation have been described in European Patent Applications 121,965; 181,044; 222,454 and 257,663, as well as U.S. Patents 4,885,318 and 4,921,897.
  • Suitable olefm units are those derived from C2 to C12 alpha-olefins and substituted derivatives thereof or styrene or alkyl substituted derivatives of styrene. It is preferred that such olefins are selected from C2 to C6 normal alpha-olefins and it is particularly preferred that the olefm units are derived from ethylene and most preferably from a mixture of ethylene and one or more C3 to C6 normal alpha-olef ⁇ n(s), especially propylene. In these most preferable materials it is further preferred that the molar ratio of ethylene units to C3 to C6 normal alpha-olefm units is greater than or equal to 1 , most preferably between 2 to 30.
  • the polyketones described above are suitably prepared by the processes described in EP 121965 or modifications thereof.
  • this comprises reacting carbon monoxide and the chosen olef ⁇ n(s) at elevated temperature and pressure with a catalyst which is preferably comprised of palladium, a bidentate phosphine, such as bis(diphenylphosphino)propane, and an anion which either does not coordinate to the palladium or coordinates only weakly.
  • a catalyst which is preferably comprised of palladium, a bidentate phosphine, such as bis(diphenylphosphino)propane, and an anion which either does not coordinate to the palladium or coordinates only weakly.
  • a catalyst which is preferably comprised of palladium, a bidentate phosphine, such as bis(diphenylphosphino)propane, and an anion which either does not coordinate to the palladium or coordinates only weakly.
  • examples of such anions include
  • polyketones with a molecular weight (average by number) from about 1,000 to 200,000, particularly of about 10,000 to 150,000, and containing substantially equimolar quantities of carbon monoxide and olefinic units derived from one or more olefins.
  • the polymer compositions of the invention may further be mixed with other polymers such as polycarbonates and polyesters such as polyethylene terephthalates or polybutyleneterephthalates. It is also possible to add polymers to improve to the impact strength (impact modifiers).
  • Impact modifiers usually comprise a rubbery part and some other comonomers. Examples are the vinylaromatic-rubbery diblock and triblock copolymers and so-called graft copolymers comprising a rubbery backbone upon which one or more monomers have been grafted.
  • compositions of this invention will generally contain from about 40 to 90 parts by weight, more preferably from about 50 to 85 parts by weight of the polyketone polymer, per 100 parts by weight of the total polymer composition.
  • Suitable such compounds include dicarboxylic acid imides including phthalimide, succinimide and salts thereof; urea and urea derivatives such as urea peroxide and urea phosphoric acid; uric acid; glycoluril; cyanuric acid and tautomer analogs thereof such as ammeline and ammelide; melamine cyanurate; allophanate; barbituric acid; allantoin; theophylline; and like nitrogen containing compounds. Most preferred compounds are those were the carboxy carbon and nitrogen atoms form part of a heterocyclic ring structure. Preferred 00/12608
  • compounds include cyanuric acid, melamine cyanurate, uric acid and glycoluril.
  • the nitrogen-containing compounds are preferably used in combination with one or more phosphorous-containing compounds as described below, since the combination appears to impart better flame retardant properties than where either component is used alone. However improved flame retardant properties can be achieved where the phosphorous-containing component is not present in the composition.
  • the nitrogen-containing compounds are included in the composition at a level of about 1 to 50 parts by weight, more preferably from about 10 to 30 parts by weight, per 100 parts by weight of the total polymer composition.
  • the polyketone polymer compositions also preferably contain one or a mixture of phosphorous- containing compounds which tend to reduce the burning behavior (burning time) properties of the polymer and also may decrease the amount of combustible volatiles generated when the polymer is subjected to burning conditions.
  • Suitable phosphorous-containing materials include inorganic phosphorous compounds such as red phosphorous and ammonium phosphate.
  • the phosphoramides useful in the invention include at least one phosphoramide of the formula:
  • R 1 is an amine residue
  • R 2 and R 3 are independently an alkoxy residue, aryloxy residue, aryloxy residue containing at least one alkyl or one halogen substitution or mixture thereof, or amine residue.
  • the phosphoramide have a glass transition point of at least about 0°C, preferably of at least about 10°C, and most preferably of at least about 20°C.
  • Another phosphoramide comprises a phosphoramide having a glass transition temperature of at least about 0°C, preferably of at least about 10°C, and most preferably of at least about 20°C, of the formula:
  • each A is independently phenyl, 2,6-dimethylphenyl, or 2,4,6- trimethylphenyl.
  • phosphorous containing compounds which may be used include bicyclic (pentaerythritol phosphate alcohol) carbonates and alkyl diaryl phosphates of the type disclosed in U.S. Patent 5,633,301 , the complete disclosure of which is incorporated herein by reference.
  • Preferred phosphorous - containing compounds are phosphine oxides, phosphonate esters, phosphinate esters, phosphoramides and (di)phosphates.
  • a phosphorous-containing compound is present in the composition, it may be included at a flame retarding level, preferably the range of about 0.5 to 25 parts by weight, more preferably from about 1 to 15 parts by weight, per 100 parts by weight of the total polymer composition.
  • composition of this invention may also contain other supplemental flame retardant additives which may serve as fillers and which at higher levels supplement the flame retardant properties of the nitrogen and phosphorous-containing flame retardants.
  • supplemental flame retardant additives include borates such as zinc or barium borate; metal hydroxides; metal oxides; metal carbonates; and mixtures thereof.
  • Suitable metal hydroxides and carbonates include alkaline earth metal hydroxides such as beryllium, magnesium, calcium, strontium and barium hydroxides, most preferably magnesium hydroxide. Pseudo-boehmite (an aluminum-oxide-hydroxide mineral) is also preferred since it functions as both a melt stabilizer for the polymer and at higher levels as a flame retardant.
  • Suitable metal carbonates include alkaline earth metal carbonates such as calcium carbonate and partially hydrated magnesium-calcium carbonate.
  • Suitable metal oxides which may be used include alumina (aluminum oxide), antimony oxide and zinc oxide When used in the composition, these supplemental additives are present at a level of from about 0.5 to 30 parts by weight, more preferably from 5 to 25 parts by weight, per 100 parts by weight of the total polymer composition.
  • compositions of this invention may also contain one or a mixture of reinforcing filler.
  • Suitable fillers include silica; silicates such as talc or mica; carbon black; and reinforcing fibers, such as carbon fiber, aramide fiber or glass fiber.
  • Glass fibers may be composed of E-glass or alkali metal silicate glass and may comprise short, chopped glass fibers with a circular cross section ranging in diameter from about 2x10 "4 to 8x10 " inch and about 0.2 to 2 cm in length. Such glass fibers are normally supplied by the manufacturers with a surface treatment compatible with the polymer component of the composition, such as a siloxane or polyurethane sizing.
  • the reinforcing filler is normally included at a level of from about 1 to 40 parts by weight, more preferably from about 5 to 35 parts by weight, per 100 parts by weight of the total polymer composition.
  • composition of this invention may also include one or more anti- dripping agents which have the properties of preventing or retarding resin from dripping while the resin is subjected to burning conditions.
  • anti- dripping agents include silicone oils, silica (which also serves as a reinforcing filler), asbestos and fluorine-containing polymers.
  • fluorine-containing polymers include fluorinated polyolefms such as polytetrafluoroethylene, tetrafluoroethylene/ hexafluoropropylene copolymers, tetrafluoroethylene/ ethylene copolymers, polyvinylidene fluoride and polychlorotrifluoroethyl ' ene.
  • Preferred such fluorine-containing polymers have a melt viscosity at 350°C of about 1.0 x 10 4 to 1.0 x 10 14 poises.
  • the anti-dripping agent is added to the composition at a level of about 0.05 to 5 parts by weight, more preferably from about 0.1 to 4 parts by weight, based on the weight of the total polymer composition.
  • the compositions of this invention may also contain other conventional additives used in polyketone polymer compositions such as stabilizers, mold release agents, plasticizers and processing aids.
  • the nitrogen-containing compound at high levels within the 1-50 parts by weight range, e.g., at least about 20 parts by weight, and also use it in combination with one or more of the supplemental flame retardants described above, e.g., zinc borate, metal oxide, metal hydroxide, metal carbonate and the like.
  • the polymer compositions of the invention are produced by mixing the flame retardants and other additives in liquid or finely divided form through the polymer.
  • the method of producing the composition is not critical so long as the method results in a relatively uniform mixture.
  • the compositions are produced by heating the polymer until molten and by mixing the flame retardant and other ingredients with the polymer by use of a high-shear mixers or extruders.
  • compositions may be processed by injection molding or other conventional thermoforming processes to produce articles useful in a variety of applications, particularly where exposure to elevated temperatures or electrical discharge is likely to be encountered.
  • the compositions are useful in the production of parts for the automotive, electrical and electronics industries, e.g., electrical connectors, circuit boards, wire insulation, conduits, printer wheels and the like.
  • the polymer compositions were prepared by dryblending the ingredients, followed by meltblending at 240°C on a PRISMTM 16MM corotating twin screw extruder with an rpm set at 300. After mixing, the melt is extruded, cooled, pelletized and dried. After drying, the pellets are molded into UL test bars with a thickness of either 0.8 mm or 1.6 mm by injection molding.
  • Lowest Oxygen Index (LOI) values were obtained on various compositions set forth in the Tables using test procedure ISO 4589. The LOI values reflect the percentage of oxygen required in an oxygen - nitrogen atmosphere to initiate and support a flame. Thus, the higher the LOI value, the more flame resistant is the sample tested.
  • Flammability of test specimens is evaluated according to the standard UL-94 test protocol, vertical burning. Ratings of V-0 indicate test samples with the best resistance to burning, whereas V-1 and V-2 ratings in that order indicate a lessening degree of resistance to burning.
  • PK polyketone polymer containing about 50 mol % carbon monoxide units, 45 mol % ethylene derived units and about 5 mol % propylene derived units, melting point of 220°C and a number average molecular weight in the range of 60,000 to 120,000.
  • AmgardTMP-45 a cyclic phosphonate ester of the type described in US Patent 5,030,674, available from Albright and Wilson in the form of a Masterbatch containing 70% by weight polyethylene terephthlate resin.
  • AmgardTMCU a mixture of cyclic phosphonate esters of the type described in US Patent 5,030,674, available for • Albright and Wilson.
  • CyagardTMRF-67 tris-cyanoethyl -phosphine oxide, available from Cytec corporation.
  • Note -NC rating means that the sample could not be classified according to UL 94VB for flammability testing.
  • the LOI is increased to 27% by the inclusion of melamine cyanurate, comparable to the ratings achieved using the phosphorous-containing compounds without melamine cyanurate.
  • Examples 5-8 show that the addition of small amounts of phosphorous-containing compounds to compositions also containing smaller amounts of melamine cyanurate result in good UL94 test ratings with also a strong improvement in LOI values.
  • test data in Table 2 demonstrates that very good LOI and UL 94 ratings are achieved using a combination of phosphorous-containing compound and melamine cyanurate.
  • Table 4 shows the variations in flame retardant properties as a function of the identity of the various P-containing compounds used. Also, the addition of a filler such as psuedo-boehmite further improves flame retardant properties.
  • Table 5 shows good burning properties for compositions containing both P and N-containing compounds.
  • Example 36 demonstrates that a combination of high levels of N-compound plus a metal-hydroxide (here pseudo-boehmite) yields good UL-classification even where the P-compound is not present in the composition.
  • a metal-hydroxide here pseudo-boehmite

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Abstract

Flame retardant compositions comprising a polyketone polymer and a flame retarding quantity of at least one nitrogen-containing compound containing the structure -C=O-NH-C=O, -NH-C=O-NH- and tautomers thereof are disclosed. The composition may optionally contain one or more additives selected from phosphorous-containing flame retardants, metal oxides or hydroxides, reinforcing fillers and anti-dripping agents.

Description

FLAME RESISTANT POLYKETONE RESIN COMPOSITIONS CROSS-REFERENCE TO RELATED APPLICATIONS
U.S. Serial Number 08/986,050 filed December 5, 1997 entitled Polyketone Flame Retardant Composition. FEDERALLY SPONSORED RESEARCH Not applicable FIELD OF THE INVENTION This invention relates to polyketone polymer compositions having improved flame retardant properties. BACKGROUND OF THE INVENTION BRIEF DESCRIPTION OF THE RELATED ART
Polymer compositions comprising polymers of carbon monoxide and at least one olefin are generally known in the art. Of particular interest in such compositions are polymer components comprising linear alternating polymers of carbon monoxide and one or more olefins, hereafter referred to as polyketones.
Polymer compositions comprising a polyketone polymers and flame retardant additives are also known in the art and have been described, for example, in U.S. Patents U.S. 4,761,449; U.S. 4,885,318; U.S. 4,885,328; U.S. 4,921,897; U.S. 5,030,674 and U.S. 5,633,301. U.S. Patent 5,030,674 discloses the use of a combination of a cyclic phosphonate ester and a polytetrafluoroethylene resin as flame retardant additives in polyketone polymer compositions. U.S. Patent 5,633,301 discloses the use of a combination of a bicyclic phosphorous compound, e.g., bis(pentaerythritol phosphate alcohol) carbonate and an intumescent flame retardant compound containing nitrogen and phosphorous, e.g., melamine phosphate, as flame retardant additives in polyketone polymer compositions. The composition may also optionally include an aryl group-containing monophosphate ester compound, e.g., triphenyl phosphate, which is said to enhance the processability of the composition. Polyketone polymer compositions can also be made flame retardant by the inclusion of halogenated organic flame retardants and/or by inclusion of inorganic metal oxides, hydroxides and carbonates in the polymer composition. Halogenated organic compounds generate toxic halogen gases 5 when subjected to burning and it is thus environmentally desirable to avoid the use of these materials, particularly at the higher levels of addition needed to achieve flame retardant properties. Inorganic metal compounds tend to increase the density of the polyketone polymer composition and their use at higher levels tends to markedly affect the physical, mechanical and melt l o stability of the polymer composition.
The present invention provides new compositions having flame retardant properties which are more friendly to the environment and which possess good physical and mechanical properties. SUMMARY OF THE INVENTION
This invention relates to flame retardant polyketone polymer
15 compositions comprising a mixture of a copolymer of carbon monoxide and at least one olefin monomer and: a) a flame retarding quantity of at least one nitrogen-containing compound which contains a chemical structure selected from the group consisting of -C=0-NH-C=0, -NH-C=0-NH- and tautomers thereof; b) 0 to 25
20 parts by weight of at least one phosphorous-containing flame retardant; c) 0 to 30 parts by weight of at least one supplemental flame retardant selected from the group consisting of metal borates, metal hydroxides, metal oxides and metal carbonates; d) 0 to 40 parts by weight of at least one reinforcing filler; and e) 0 to 5 parts by weight of at least one anti-dripping agent which
25 retards the tendency of the composition to drip when subjected to burning conditions; said parts by weight based on the total weight of the polymer composition.
Compositions in accordance with this invention exhibit good flame retardant properties while maintaining a good balance in mechanical, and
30 physical properties. DESCRIPTION OF THE DRAWINGS
Not applicable.
DESCRIPTION OF THE INVENTION
The polymers used in the polymer compositions of the invention are meant to include all polymers containing units derived from carbon monoxide and units derived from one or more olefins. This definition includes both random polymers produced by radical polymerization and linear alternating polymers, hereafter all referred to as polyketones. Suitable polyketones and processes for their preparation have been described in European Patent Applications 121,965; 181,044; 222,454 and 257,663, as well as U.S. Patents 4,885,318 and 4,921,897.
Suitable olefm units are those derived from C2 to C12 alpha-olefins and substituted derivatives thereof or styrene or alkyl substituted derivatives of styrene. It is preferred that such olefins are selected from C2 to C6 normal alpha-olefins and it is particularly preferred that the olefm units are derived from ethylene and most preferably from a mixture of ethylene and one or more C3 to C6 normal alpha-olefιn(s), especially propylene. In these most preferable materials it is further preferred that the molar ratio of ethylene units to C3 to C6 normal alpha-olefm units is greater than or equal to 1 , most preferably between 2 to 30.
The polyketones described above are suitably prepared by the processes described in EP 121965 or modifications thereof. In general terms, this comprises reacting carbon monoxide and the chosen olefιn(s) at elevated temperature and pressure with a catalyst which is preferably comprised of palladium, a bidentate phosphine, such as bis(diphenylphosphino)propane, and an anion which either does not coordinate to the palladium or coordinates only weakly. Examples of such anions include p- toluenesulfonate, tetrafluoroborate, borosalicylate and the like. The process is suitably carried out at a temperature in the range 50 to 150C, a pressure in the range 25 to 70 bar gauge and in a solvent such as methanol, acetone, THF or the like.
Of particular interest are the polyketones with a molecular weight (average by number) from about 1,000 to 200,000, particularly of about 10,000 to 150,000, and containing substantially equimolar quantities of carbon monoxide and olefinic units derived from one or more olefins.
The polymer compositions of the invention may further be mixed with other polymers such as polycarbonates and polyesters such as polyethylene terephthalates or polybutyleneterephthalates. It is also possible to add polymers to improve to the impact strength (impact modifiers). Impact modifiers usually comprise a rubbery part and some other comonomers. Examples are the vinylaromatic-rubbery diblock and triblock copolymers and so-called graft copolymers comprising a rubbery backbone upon which one or more monomers have been grafted.
The compositions of this invention will generally contain from about 40 to 90 parts by weight, more preferably from about 50 to 85 parts by weight of the polyketone polymer, per 100 parts by weight of the total polymer composition.
The polyketone polymer compositions of this invention contain a flame retarding quantity of one or a mixture of nitrogen-containing compounds which contain a chemical structure of the class -C=0-NH-C=0 or -NH-C=0- NH-, and also include the tautomeric structure. Suitable such compounds include dicarboxylic acid imides including phthalimide, succinimide and salts thereof; urea and urea derivatives such as urea peroxide and urea phosphoric acid; uric acid; glycoluril; cyanuric acid and tautomer analogs thereof such as ammeline and ammelide; melamine cyanurate; allophanate; barbituric acid; allantoin; theophylline; and like nitrogen containing compounds. Most preferred compounds are those were the carboxy carbon and nitrogen atoms form part of a heterocyclic ring structure. Preferred 00/12608
compounds include cyanuric acid, melamine cyanurate, uric acid and glycoluril.
The nitrogen-containing compounds are preferably used in combination with one or more phosphorous-containing compounds as described below, since the combination appears to impart better flame retardant properties than where either component is used alone. However improved flame retardant properties can be achieved where the phosphorous-containing component is not present in the composition. Generally, the nitrogen-containing compounds are included in the composition at a level of about 1 to 50 parts by weight, more preferably from about 10 to 30 parts by weight, per 100 parts by weight of the total polymer composition.
The polyketone polymer compositions also preferably contain one or a mixture of phosphorous- containing compounds which tend to reduce the burning behavior (burning time) properties of the polymer and also may decrease the amount of combustible volatiles generated when the polymer is subjected to burning conditions. Suitable phosphorous-containing materials include inorganic phosphorous compounds such as red phosphorous and ammonium phosphate. Organic phosphates which may be used include mono or di-melamine phosphate; alky I, aryl and mixed aralkyl phosphates and phosphonates such as triethyl phosphate, dimethyl methylphosphonate, triphenyl phosphate, tricresyl phosphate and alkyl diphenyl phosphates; diphosphates such as bisphenol A diphosphate, resorcinoldiphosphate and the reaction product of bis(2-chloroethyl) phosphorochloridate and ethylene glycol; halogenated alkyl phosphates and phosphonates such as 2- chloroethanol phosphate, 1,3-dichloro-2-propanol phosphate and bis(2- chloroethyi)2-chloroethylphosphonate; phosphoramides such as tetraxylyl piperazine diphosphoramide; phosphine oxides of the structure Ri R2 R3 - P =0 wherein R1f R2 and R3 are alkyl, hydroxy alkyl, cyanoalkyl, phenyl or benzyl such as triphenylphosphine oxide and tris-cyanoethyl phosphine oxide; phosphorous containing diols and polyols such as the reaction product of propylene oxide and dibutyl acid pyrophosphate; phosphinates such as 1 ,4-diisobutyl - 2, 3, 5, 6 - tetrahydroxy - 1,4-dioxa -1,4- diphosphorinane; oligomeric phosphites; oligomeric phosphorous esters; and oligomeric cyclic phosphonates such as the type disclosed in U.S. Patent 5,030,674, the complete disclosure of which is incorporated hereby by reference.
The phosphoramides useful in the invention include at least one phosphoramide of the formula:
Figure imgf000008_0001
wherein R1 is an amine residue, and R2 and R3 are independently an alkoxy residue, aryloxy residue, aryloxy residue containing at least one alkyl or one halogen substitution or mixture thereof, or amine residue. It is preferred that the phosphoramide have a glass transition point of at least about 0°C, preferably of at least about 10°C, and most preferably of at least about 20°C. When a phosphoramide having a glass transition point of at least about 0°C is used as a source of phosphorous in resin compositions, it was unexpectedly found that a higher heat deflection temperature of test specimens made from the resin composition could be obtained as compared to compositions containing an organophosphate ester known in the art.
Another phosphoramide comprises a phosphoramide having a glass transition temperature of at least about 0°C, preferably of at least about 10°C, and most preferably of at least about 20°C, of the formula:
Figure imgf000008_0002
wherein each A is independently phenyl, 2,6-dimethylphenyl, or 2,4,6- trimethylphenyl.
Other phosphorous containing compounds which may be used include bicyclic (pentaerythritol phosphate alcohol) carbonates and alkyl diaryl phosphates of the type disclosed in U.S. Patent 5,633,301 , the complete disclosure of which is incorporated herein by reference. Preferred phosphorous - containing compounds are phosphine oxides, phosphonate esters, phosphinate esters, phosphoramides and (di)phosphates.
Where a phosphorous-containing compound is present in the composition, it may be included at a flame retarding level, preferably the range of about 0.5 to 25 parts by weight, more preferably from about 1 to 15 parts by weight, per 100 parts by weight of the total polymer composition.
The composition of this invention may also contain other supplemental flame retardant additives which may serve as fillers and which at higher levels supplement the flame retardant properties of the nitrogen and phosphorous-containing flame retardants. Such additives include borates such as zinc or barium borate; metal hydroxides; metal oxides; metal carbonates; and mixtures thereof.
Suitable metal hydroxides and carbonates include alkaline earth metal hydroxides such as beryllium, magnesium, calcium, strontium and barium hydroxides, most preferably magnesium hydroxide. Pseudo-boehmite (an aluminum-oxide-hydroxide mineral) is also preferred since it functions as both a melt stabilizer for the polymer and at higher levels as a flame retardant. Suitable metal carbonates include alkaline earth metal carbonates such as calcium carbonate and partially hydrated magnesium-calcium carbonate.
Suitable metal oxides which may be used include alumina (aluminum oxide), antimony oxide and zinc oxide When used in the composition, these supplemental additives are present at a level of from about 0.5 to 30 parts by weight, more preferably from 5 to 25 parts by weight, per 100 parts by weight of the total polymer composition.
The compositions of this invention may also contain one or a mixture of reinforcing filler. Suitable fillers include silica; silicates such as talc or mica; carbon black; and reinforcing fibers, such as carbon fiber, aramide fiber or glass fiber. Glass fibers may be composed of E-glass or alkali metal silicate glass and may comprise short, chopped glass fibers with a circular cross section ranging in diameter from about 2x10"4 to 8x10" inch and about 0.2 to 2 cm in length. Such glass fibers are normally supplied by the manufacturers with a surface treatment compatible with the polymer component of the composition, such as a siloxane or polyurethane sizing. When used in the composition, the reinforcing filler is normally included at a level of from about 1 to 40 parts by weight, more preferably from about 5 to 35 parts by weight, per 100 parts by weight of the total polymer composition.
The composition of this invention may also include one or more anti- dripping agents which have the properties of preventing or retarding resin from dripping while the resin is subjected to burning conditions. Specific examples of such agents include silicone oils, silica (which also serves as a reinforcing filler), asbestos and fluorine-containing polymers. Examples of fluorine-containing polymers include fluorinated polyolefms such as polytetrafluoroethylene, tetrafluoroethylene/ hexafluoropropylene copolymers, tetrafluoroethylene/ ethylene copolymers, polyvinylidene fluoride and polychlorotrifluoroethyl'ene. Preferred such fluorine-containing polymers have a melt viscosity at 350°C of about 1.0 x 104 to 1.0 x 1014 poises. When used, the anti-dripping agent is added to the composition at a level of about 0.05 to 5 parts by weight, more preferably from about 0.1 to 4 parts by weight, based on the weight of the total polymer composition. The compositions of this invention may also contain other conventional additives used in polyketone polymer compositions such as stabilizers, mold release agents, plasticizers and processing aids.
As indicated above, where the polyketone polymer composition is free of the phosphorous-containing compounds, it is preferable to employ the nitrogen-containing compound at high levels within the 1-50 parts by weight range, e.g., at least about 20 parts by weight, and also use it in combination with one or more of the supplemental flame retardants described above, e.g., zinc borate, metal oxide, metal hydroxide, metal carbonate and the like.
The polymer compositions of the invention are produced by mixing the flame retardants and other additives in liquid or finely divided form through the polymer. The method of producing the composition is not critical so long as the method results in a relatively uniform mixture. In a preferred embodiment the compositions are produced by heating the polymer until molten and by mixing the flame retardant and other ingredients with the polymer by use of a high-shear mixers or extruders.
The compositions may be processed by injection molding or other conventional thermoforming processes to produce articles useful in a variety of applications, particularly where exposure to elevated temperatures or electrical discharge is likely to be encountered. The compositions are useful in the production of parts for the automotive, electrical and electronics industries, e.g., electrical connectors, circuit boards, wire insulation, conduits, printer wheels and the like.
In the following examples, the polymer compositions were prepared by dryblending the ingredients, followed by meltblending at 240°C on a PRISM™ 16MM corotating twin screw extruder with an rpm set at 300. After mixing, the melt is extruded, cooled, pelletized and dried. After drying, the pellets are molded into UL test bars with a thickness of either 0.8 mm or 1.6 mm by injection molding. Lowest Oxygen Index (LOI) values were obtained on various compositions set forth in the Tables using test procedure ISO 4589. The LOI values reflect the percentage of oxygen required in an oxygen - nitrogen atmosphere to initiate and support a flame. Thus, the higher the LOI value, the more flame resistant is the sample tested.
Flammability of test specimens is evaluated according to the standard UL-94 test protocol, vertical burning. Ratings of V-0 indicate test samples with the best resistance to burning, whereas V-1 and V-2 ratings in that order indicate a lessening degree of resistance to burning.
Materials identified in Tables 1r6 by abbreviations or trade names are as follows:
PK polyketone polymer containing about 50 mol % carbon monoxide units, 45 mol % ethylene derived units and about 5 mol % propylene derived units, melting point of 220°C and a number average molecular weight in the range of 60,000 to 120,000.
Amgard™P-45 a cyclic phosphonate ester of the type described in US Patent 5,030,674, available from Albright and Wilson in the form of a Masterbatch containing 70% by weight polyethylene terephthlate resin.
Amgard™CU a mixture of cyclic phosphonate esters of the type described in US Patent 5,030,674, available for Albright and Wilson.
RDP resorcinol diphosphate
Cyagard™RF-67 tris-cyanoethyl -phosphine oxide, available from Cytec corporation. Cyagard .T"M"RF-1204 1 ,4 diisobutyl-2,3,5,6 - tetrahydroxy-1 ,4 -dioxa -1,4 diphosphorinane, available from Cytec Corporation.
BPA diphosphate -bisphenol A-diphosphate
TPPO triphenylphosphineoxide.
X4PIP tetraxylyl piperazine diphosphoramide.
AMMP aluminum-methyl-methylphosphonate
Figure imgf000013_0001
PTFE polytetrafluoroethylene
Glass glass fibers of type T351 from Nippon Electric Glass or experimental fibers from Pittsburg Plate and Glass
Co.
Formulations and test results are shown in Tables 1-6 as Examples 1- 44. Examples identified with the Letter C are control examples outside the scope of the invention. Amounts are parts by weight.
O 00/12608
Table 1
Ex 1c 3c 4c 8
PK 67.8 47.5 58.1 58.1 49.1 44.4 49.1 44
Mel.Cyanura 20 14 14 14 14 te
Amgard P45 9.4 4.7 9.4
Amgard CU 9.4 4.7 9.4
PTFE 0.3 0.3 0.3
Stabilizer 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2
Glass 30 30 30 30 30 30 30 30
UL- NC NC NC NC V0 VO V1 VO
94; 1.6mm
LOI 20.5 27 27 26.5 32 38.5 31 38
Note -NC rating means that the sample could not be classified according to UL 94VB for flammability testing.
As shown in Table 1 , the LOI is increased to 27% by the inclusion of melamine cyanurate, comparable to the ratings achieved using the phosphorous-containing compounds without melamine cyanurate. Examples 5-8 show that the addition of small amounts of phosphorous-containing compounds to compositions also containing smaller amounts of melamine cyanurate result in good UL94 test ratings with also a strong improvement in LOI values.
Table 2
Ex 9c 10c 11 12c 13 14 15c 16
PK 98.5 88 78.5 88 78.5 78.5 88.5 68.5
Mel. — — 20 — 14 10 — 30 Cyanurate
Amgard P-45 — 10 — — — — — —
Amgard Cu — — — 10 6 10 10 —
PTFE — 0.5 — 0.5 — — —
Stabilizer 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
UL94; 1.6mm NC VO V2 VO VO VO V2 V2
LOI 18.5 26 25 25.5 28 27.5 25 25.5
The test data in Table 2 demonstrates that very good LOI and UL 94 ratings are achieved using a combination of phosphorous-containing compound and melamine cyanurate.
O 00/12608
Table 3
Ex 17 18 19 20 21
PK 66 45.6 65.5 65.5 65.5
Mel. Cyanurate — 14 10
Uric Acid mmm -,MM mm^^ 10 -—
Glycoluril — — — — 10
Cyanuric Acid 10 — — — —
Amgard P-45 8 — 8 8 8
AMMP — 8.2 — — —
Stabilizer 1 2.2 1.5 1.5 1.5
Glass 15 30 15 15 15
UL-94; 1.6mm VO V1 V1 V1 V1
The test data in Table 3 demonstrates that good UL-94 burning ratings were achieved using a combination of P and N-containing compounds. O 00/12608
Table 4
Ex. 22 23 24 25 26 27 28
PK 59 59 59 59 59 59 40
Mel. Cyanurate 15 15 15 15 15 15 15
Amgard CU — — — 10 — — —
RDP 10 — — — —
Cyagard RF 1204 — - 10 -— — -— —
Cyagard RF-67 — — 10 — — — 10
BPA-diphosphate — — — — 10 — —
TPPO _ -_- __ _ — 10 -—
pseudo-boehmite — — — — — — 19
Stabilizer 1 1 1 1 1 1 1
glass 15 15 15 15 15 15 15
UL94;0.8mm V1 V0 V1 V0 V2 V1 VO
UL94; 1.6mm V1 VO V1 VO NC NC V0V1
The data in Table 4 shows the variations in flame retardant properties as a function of the identity of the various P-containing compounds used. Also, the addition of a filler such as psuedo-boehmite further improves flame retardant properties.
00/12608
Table 5
Ex. 29 30 31 32 33 34 35 36
PK 58 53 60 53 70 59 47 50
Mel. Cyanurate — 15 — 15 — — — —
Uric Acid 15 — 8 — 5 25 25 25
Cyagard 7 12 12 12 — — — — RF1204
Cyagard RF-67 — — — — — — 12 —
Pseudo- 4 4 4 4 9 — — 9 boehmite
Stabilizer 1 1 1 1 1 1 1 1
glass 15 15 15 15 15 15 15 15
UL-94;0.8mm V1 V1 V1 V1 V2 V2 VO V1
UL-94; 1.6mm V1 V1 V1 V1
Table 5 shows good burning properties for compositions containing both P and N-containing compounds. Example 36 demonstrates that a combination of high levels of N-compound plus a metal-hydroxide (here pseudo-boehmite) yields good UL-classification even where the P-compound is not present in the composition. 00/12608
Table 6
Ex. 37 38 39 40 41 42 43 44
PK 59 69 56.5 54 66.5 64 53.5 49.5
Mel. 25 15 25 25 15 15 24 24 Cyanurate
Cyagard RF- — — 2.5 5 2.5 5 — — 67
X4PIP — __ __ __ __ 4 8
Stabilizer 1 1 1 1 1 1 3.5 3.5
glass 15 15 15 15 15 15 15 15
UL-94;0.8mm NC V2
UL-94; 1.6mm V1 V1 V2 V1 V1 V1
Table 6 demonstrates that the use of relatively high amounts of N- compound (15-25%) gives good UL classification even where only small amounts of P-compound are present and no other auxiliary flame retardants are present.

Claims

CLAIMS What is claimed is:
1. A polyketone polymer composition comprising a mixture of a copolymer of carbon monoxide and at least one olefm monomer and:
a) a flame retarding quantity of at least one nitrogen-containing compound which contains a chemical structure selected from the group consisting of -C=0-NH-C=O, -NH-C=0-NH- and tautomers thereof;
b) 0 to 25 parts by weight of at least one phosphorous-containing flame retardant;
c) 0 to 30 parts by weight of at least one supplemental flame retardant selected from the group consisting of metal borates, metal hydroxides, metal oxides and metal carbonates;
d) 0 to 40 parts by weight of at least one reinforcing filler; and
e) 0 to 5 parts by weight of at least one anti-dripping agent which retards the tendency of the composition to drip when subjected to burning conditions;
said parts by weight based on the total weight of the
polymer composition.
2. The composition of claim 1 wherein said phoshorous-containing flame retardant is selected from the group consisting of phosphates, phosphites, phosphonates, phosphinates, phosphine-oxides and phosphoramides.
3. The composition of claim 1 wherein said phosphorous-containing flame retardant comprises at least one phosphoramide of the formula:
Figure imgf000023_0001
wherein R1 is an amine residue, and R2 and R3 are independently an alkoxy residue, aryloxy residue, aryloxy residue containing at least one alkyl or one halogen substitution or mixture thereof, or amine residue.
4. The composition of claim 1 wherein said phosphorous-containing flame retardant comprises phosphoramide comprises a phosphoramide having a glass transition temperature of at least about 0°C, preferably of at least about 10°C, and most preferably of at least about 20°C, of the formula:
Figure imgf000024_0001
wherein each A is independently phenyl, 2,6-dimethylphenyl, or 2,4,6- trimethylphenyl.
5. The composition of claim 1 containing from about 1 to 50 parts by weight of said nitrogen-containing flame retardant.
6. The composition of claim 5 containing from about 10 to 30 parts by weight of said nitrogen-containing flame retardant.
7. The composition of claim 6 containing from about 0.5 to 30 parts by weight of said supplemental flame retardant.
8. The composition of claim 7 wherein said supplemental flame retardant is pseudo-boehmite.
9. The composition of claim 8 containing at least about 1 part by weight of said reinforcing filler.
10. The composition of claim 9 wherein said reinforcing filler is selected from the group consisting of silica, silicates, carbon black and glass or polymeric reinforcing fibers.
11. The composition of claim 10 wherein said reinforcing filler is glass fiber.
12. The composition of claim 1 containing at least about 0.05 parts by weight of said anti-dripping agent.
13. The composition of claim 12 wherein said anti-chopping agent is a fluorine-containing polymer.
14. The composition of claim 1 containing from about 40 to 90 parts by weight of said copolymer of carbon monoxide and at least one olefin monomer.
15. The composition of claim 1 wherein said olefin-monomer is ethylene or a mixture of ethylene and at least one C3 to Cθ alpha-olefin.
16. A polyketone polymer composition comprising a mixture of a copolymer of carbon monoxide and at least one olefin monomer and:
a) a flame retarding quantity of at least one phosphorous-containing flame retardant;
b) 0 to 40 parts by weight of at least one reinforcing filler; and
c) 0 to 5 parts by weight of at least one anti-dripping agent which retards the tendency of the composition to drip when subjected to burning conditions; said parts by weight based on the total weight of the polymer composition, said phosphorous-containing flame retardant comprising a phosphoramide having a glass transition temperature of at least about 0°C, preferably of at least about 10°C, and most preferably of at lest about 20°C, of the formula:
Figure imgf000025_0001
wherein each A is independently phenyl, 2,6-dimethylphenyl, or 2,4,6- trimethylphenyl
PCT/US1999/017224 1998-08-31 1999-07-30 Flame resistant polyketone resin compositions Ceased WO2000012608A1 (en)

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