Flame-retarded styrene-containing formulations

Patent metadata

Field	Value
Publication number	US-11111376-B2
Application number	US-201816497790-A
Country	US
Kind code	B2
Filing date	Mar 28, 2018
Priority date	Mar 30, 2017
Publication date	Sep 7, 2021
Grant date	Sep 7, 2021

Abstract

A composition comprising: an impact modified styrene-containing polymer; at least one bromine-containing flame retardant; at least one dialkyl phosphinic acid metal salt M1n+(R1R2PO2)n wherein M1 is a metal cation with valence n and R1, R2 are alkyl groups which may be the same or different; at least one anti-dripping agent, wherein the total concentration of the bromine-containing flame retardant and the dialkyl phosphinic acid metal salt is less than 28% by weight based on the sum of all components in the composition, wherein said composition is free of antimony and meets UL-94 V-1/1.6 mm or UL-94 V-0/1.6 mm test requirements.

First claim

The invention claimed is:

1. A composition comprising:
an impact modified styrene-containing polymer; wherein the impact modified styrene-containing polymer is selected from the group consisting of acrylonitrile-butadiene-styrene (ABS) and high impact polystyrene (HIPS);
at least one bromine-containing flame retardant;
at least one metal hypophosphite salt Mq+(H 2 PO 2 ) q , wherein M indicates a metal cation with valence q; and
at least one anti-dripping agent,
wherein the total concentration of the bromine-containing flame retardant and the metal hypophosphite is less than 28% by weight based on the sum of all components in the composition, wherein the bromine concentration of the composition is from 9.5 to 15.5% by weight based on the total weight of the composition, wherein the composition is antimony-free and meets UL-94 V-1/1.6 mm or UL-94 V-0/1.6 mm test requirements.

2. A composition according to claim 1 , wherein the total concentration of the bromine-containing flame retardant and the metal hypophosphite is from 18 to 26% by weight.

3. A composition according to claim 1 , wherein the concentration of the metal hypophosphite is from 2 to 9% by weight based on the total weight of the composition.

4. A composition according to claim 1 , wherein the bromine-containing flame retardant has bromine content of 50% to 70% by weight and its bromine atoms are either all aromatically-bound or all aliphatically-bound and the metal hypophosphite is aluminum hypophosphite, calcium hypophosphite or a mixture thereof.

5. A composition according to claim 4 , wherein the bromine-containing flame retardant is selected from the group consisting of:
(i) Tris(2,4,6-tribromophenoxy)-s-triazine represented by the following formula:

(ii) Tris(tribromoneopentyl) phosphate represented by the following formula:

iii) Tetrabromobisphenol A represented by the following formula:

iv) brominated epoxy resins and end-capped derivatives thereof, represented by the formula:

wherein m indicates degree of polymerization, R 1 and R 2 are independently selected from the group consisting of:

6. A composition according to claim 5 , wherein the bromine-containing flame retardant is tris(2,4,6-tribromophenoxy)-s-triazine.

7. A composition according to claim 6 , comprising from 60 to 80% by weight of ABS or HIPS, from 15 to 20% by weight of tris(2,4,6-tribromophenoxy)-s-triazine, from 3 to 9% by weight of Al(H 2 PO 2 )3, Ca(H 2 PO 2 )2 or a mixture thereof and from 0.1 to 0.5% by weight of polytetrafluoroethylene, based on the total weight of the composition.

8. A composition according to claim 5 , wherein the bromine-containing flame retardant is tris(tribromoneopentyl) phosphate.

9. A composition according to claim 8 , comprising from 60 to 80% by weight of ABS, from 15 to 20% by weight of tris(tribromoneopentyl) phosphate, from 3 to 9% by weight of Al(H 2 PO 2 )3, Ca(H 2 PO 2 )2 or a mixture thereof and from 0.1 to 0.5% by weight of polytetrafluoroethylene based on the total weight of the composition.

10. A composition according to claim 5 , wherein the bromine-containing flame retardant is tetrabromobisphenol A.

11. A composition according to claim 10 , comprising from 60 to 80% by weight of ABS, from 18 to 23% by weight of tetrabromobisphenol A, from 3 to 9% by weight of Al(H 2 PO 2 )3, Ca(H 2 PO 2 )2 or a mixture thereof and from 0.1 to 0.5% by weight of polytetrafluoroethylene based on the total weight of the composition.

12. A composition according to claim 5 , wherein the bromine-containing flame retardant is tribromophenol end-capped low-molecular weight resin represented by the following Formula (IVa) and mixtures thereof:

wherein m is an integer in the range between 0 and 5 with number-average molecular weight from 1300 to 2500.

13. A composition according to claim 12 , comprising from 60 to 80% by weight of ABS, from 18 to 23% by weight of tribromophenol end-capped low-molecular weight epoxy resin of Formula IVa, from 3 to 9% by weight of Al(H 2 PO 2 )3, Ca(H 2 PO 2 )2 or a mixture thereof and from 0.1 to 0.5% by weight of polytetrafluoroethylene based on the total weight of the composition.

14. A composition according to claim 13 , wherein the composition further comprises an additive selected from the group consisting of aryl phosphate ester of hydroquinone, polydimethylsiloxane and novolac epoxy resins.

15. A composition according to claim 14 , wherein the bromine concentration of the composition is from 10 to 15% by weight and the bromine/metal hypophosphite(s) weight ratio is greater than 2:1.

16. A composition according to claim 15 , wherein the bromine/metal hypophosphite(s) weight ratio is from 3:1 to 7:1.

17. A composition according to claim 14 , comprising from 60 to 80% by weight of ABS, from 15 to 20% by weight of tris(2,4,6-tribromophenoxy)-s-triazine, from 3 to 6% by weight of Al (H 2 PO 2 ) 3 , Ca(H 2 PO 2 ) 2 or a mixture thereof, from 1 to 10% by weight of a combination consisting of aryl phosphate ester of hydroquinone and at least one of polydimethylsiloxane and novolac epoxy resins, and from 0.1 to 0.5% by weight of polytetrafluoroethylene based on the total weight of the composition.

18. A composition according to claim 14 , comprising ABS, 10 to 15% by weight bromine supplied by the bromine-containing flame retardant, Ca(H2P02)2 and polydimethylsiloxane wherein the weight ratio bromine: Ca(H 2 PO 2 )2 is greater than 2:1 and the weight ratio Ca(H 2 PO 2 )2: polydimethylsiloxane is from 7:1 to 1:2.

19. A composition according to claim 18 , wherein the total concentration of the Ca(H 2 PO 2 )2 +polydimethylsiloxane mixture is from 4 to 7% by weight based on the total weight of the composition.

20. A composition according to claim 19 , comprising from 70 to 80% ABS, from 15 to 22.5% by weight of tris(2,4,6-tribromophenoxy)-s-triazine, from 2.0 to 5.0% by weight of Ca(H 2 PO 2 )2, from 0.5 to 4.0% polydimethylsiloxane and from 0.1 to 0.5% by weight of polytetrafluoroethylene based on the total weight of the composition.

21. A composition according to claim 13 , further comprising from 0.5 to 3% by weight of talc based on the total weight of the composition.

22. A composition according to claim 21 , comprising from 60 to 80% by weight of ABS, from 13 to 18% by weight of tris(2,4,6-tribromophenoxy)-s-triazine, from 4 to 8% by weight of Al(H 2 PO 2 ) 3, Ca(H 2 PO 2 ) 2 or a mixture thereof, from 0.5 to 3% by weight of talc and from 0.1 to 0.5% by weight of polytetrafluoroethylene based on the total weight of the composition.

23. A molded article comprising the composition of claim 1 .

Assignees

• Bromine Compounds Ltd

Inventors

• Hirschsohn Yaniv
• Eden Eyal

Classifications

• C08L55/02 Primary

  ABS [Acrylonitrile-Butadiene-Styrene] polymers · CPC title

• C08G59/1455

  Monocarboxylic acids, anhydrides, halides, or low-molecular-weight esters thereof · CPC title

• C08L27/18

  Homopolymers or copolymers or tetrafluoroethene · CPC title

• C08K5/06

  Ethers; Acetals; Ketals; Ortho-esters · CPC title

• C08L63/04

  Epoxynovolacs · CPC title