High frequency weldable ethylene-based polymer compositions with good flame retardancy

Patent metadata

Field	Value
Publication number	US-10221304-B2
Application number	US-201515502892-A
Country	US
Kind code	B2
Filing date	Sep 30, 2015
Priority date	Oct 2, 2014
Publication date	Mar 5, 2019
Grant date	Mar 5, 2019

Abstract

The invention provides a composition comprising at least the following components: A) a first composition comprising a first ethylene/α-olefin block copolymer consisting of ethylene and C 4 -C 8 α-olefin comonomer; and where the first composition has a density from 0.87 g/cc to 0.90 g/cc, and a melt index (I 2 ) from 6.0 to 20.0 g/10 min; B) at least one filler that is capable of being excited by an alternating electromagnetic field at a frequency greater than, or equal to 10 MHz; C) at least one flame retardant selected from the group consisting of i) from 30.0 to 50.0 wt % of one or more non-halogen, inorganic flame retardant compounds, based on the weight of the composition; and ii) from 8.0 to 30.0 wt % of one or more halogen-containing flame retardant compounds, based on the weight of the composition; and D) at least one polar polymer.

First claim

The invention claimed is:

1. A composition comprising at least the following components:
A) a first composition comprising a first ethylene/α-olefin block copolymer consisting of ethylene and C 4 -C 8 α-olefin comonomer; and where the first composition has a density from 0.87 g/cc to 0.90 g/cc, and a melt index (I2) from 6.0 to 20.0 g/10 min;
B) at least one filler that is capable of being excited by an alternating electromagnetic field at a frequency greater than, or equal to 10 MHz;
C) at least one flame retardant selected from the group consisting of
i) from 30.0 to 50.0 wt % of one or more non-halogen, inorganic flame retardant compounds, based on the weight of the composition; and
ii) from 8.0 to 30.0 wt % of one or more halogen-containing flame retardant compounds, based on the weight of the composition; and

D) at least one polar polymer.

2. The composition of claim 1 , wherein the polar polymer is selected from the group consisting of an ethylene vinyl acetate (EVA), a chlorinated ethylene-based polymer copolymer; a maleic anhydride functionalize olefin-based polymer; an ethylene-acrylic acid copolymer; an ethylene-acrylate copolymer; and a combination thereof.

3. The composition of claim 1 , wherein the first composition further comprises a second ethylene/α-olefin block copolymer consisting of ethylene and C 4 -C 8 α-olefin comonomer, wherein the second ethylene/α-olefin block copolymer is different than the first ethylene/α-olefin block copolymer.

4. The composition of claim 3 , wherein the weight ratio of the first ethylene/α-olefin block copolymer to the second ethylene/α-olefin block copolymer is from 0.8 to 1.2.

5. The composition of claim 4 , wherein the density ratio of the first ethylene/α-olefin block copolymer to the second ethylene/α-olefin block copolymer is from 0.8 to 1.2.

6. The composition of claim 3 , wherein the I2 ratio of the first ethylene/α-olefin block copolymer to the second ethylene/α-olefin block copolymer is from 0.10 to 0.60.

7. The composition of claim 1 , wherein the composition has a density from 1.2 to 1.4 g/cc.

8. The composition of claim 1 , wherein the composition has an I2 from 0.1 to 2.0 g/10 min.

9. The composition of claim 1 , wherein the composition has an I10 from 2.0 to 20.

10. The composition of claim 1 , wherein the composition has a ratio I10/I2 from 10 to 50.

11. The composition of claim 1 , wherein the composition has a % mass loss (NFPA 701 test method) less than, or equal to 5 wt %.

12. An article comprising at least one component formed from the composition of claim 1 .

13. The composition of claim 1 comprising from 10 wt % to 30 wt % filler comprising a zeolite.

14. The composition of claim 1 , wherein the polar polymer is comprises a chlorinated ethylene-based polymer copolymer.

15. The composition of claim 1 , wherein the flame retardant is the non-halogen, inorganic flame retardant compound; and
the weight ratio of the first composition to the flame retardant is from 0.35 to 0.75.

16. The composition of claim 1 , wherein the flame retardant is the halogen-containing flame retardant compound; and
the weight ratio of the first composition to the flame retardant is from 1.90 to 5.50.

17. The composition of claim 1 , wherein the composition has
a Shore A Hardness from 70 to 92; and
a melting point from 115° C. to 135° C.

18. The composition of claim 3 comprising
A) the first composition comprising
i) from 5 wt % to 25 wt % of the first ethylene/α-olefin block copolymer, based on the total weight of the composition;
ii) from 5 wt % to 25 wt % of the second ethylene/α-olefin block copolymer;

B) from 10 wt % to 30 wt % filler comprising a zeolite;
C) from 30.0 to 50.0 wt % of the non-halogen, inorganic flame retardant compound, wherein the weight ratio of the first composition to non-halogen, inorganic flame retardant compound is from 0.35 to 0.75;
D) from 15 wt % to 40 wt % of the polar polymer;
wherein the composition passes the standard NFPA 701 test method 1, and the composition has
i) a Shore A Hardness from 70 to 92;
ii) a melting point from 115° C. to 135° C.

19. An article comprising
a first film and a second film, the first film and the second film each comprising the composition of claim 18 ;
a radio frequency (RF) weld that seals the first film to the second film; and
the RF weld does not separate when the first film and the second film are hand-pulled apart.

Assignees

• Dow Global Technologies Llc

Inventors

• Li Guang Ming
• Weaver Laura B
• Cogen Jeffrey M
• Ultsch Stefan

Classifications

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• C08L2201/02

  Flame or fire retardant/resistant · CPC title

• C08L53/00 Primary

  Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers · CPC title

• C08L23/286 Primary

  Chlorinated polyethylene · CPC title

• C08L23/0869

  with unsaturated acids, e.g. [meth]acrylic acid; with unsaturated esters, e.g. [meth]acrylic acid esters · CPC title