Flame retardant epoxy resins comprising phosphorus containing flame retardants

Patent metadata

Field	Value
Publication number	US-9534108-B2
Application number	US-201514717348-A
Country	US
Kind code	B2
Filing date	May 20, 2015
Priority date	Mar 13, 2015
Publication date	Jan 3, 2017
Grant date	Jan 3, 2017

Abstract

Resin compositions, e.g., epoxy resin compositions, comprising flame retardant materials obtained by heating phosphonic acid salts at temperatures above 200° C., have excellent properties and exhibit manageable curing behavior. Laminates, composites, molded articles and the like, which have excellent flame retardant properties and physical characteristics, are readily prepared from the resin compositions of the invention.

First claim

What is claimed:

1. A flame retardant epoxy resin composition comprising
a) an epoxy resin,
b) from 1% to 60%, by weight based on the total weight of the flame retardant epoxy resin composition, of a flame retardant material obtained by a process comprising heating at temperatures of about 200° C. or higher from about 0.01 hour to about 20 hours one or more than one compound of formula (I)

 wherein
R is C 1-12 alkyl, C 6-10 aryl, C 7-15 alkylaryl, or C 7-15 arylalkyl, wherein said alkyl, aryl, alkylaryl, or arylalkyl are unsubstituted or are substituted by halogen, hydroxyl, amino, C 1-4 alkylamino, di-C 1-4 alkylamino, C 1-4 alkoxy, carboxy or C 2-5 alkoxycarbonyl;
M is a metal,
y is a number of from 1 to 4 so that M (+)y is a metal cation where (+)y represents the charge formally assigned to the cation, and p is a number of from 1 to 4, and

c) a curing agent.

2. The flame retardant epoxy resin composition according to claim 1 wherein the flame retardant material (b) is obtained by a process comprising:
i) preparing an intermediate salt complex by treating one or more phosphonic acid compound with one or more appropriate metal compound to give an intermediate salt complex corresponding to formula (I) comprising multiple values for R and/or M, and then heating the intermediate salt complex at temperatures of about 200° C. or higher for about 0.01 hour to about 20 hours;

or
ii) preparing an intimate salt mixture by combining two or more individual metal phosphonic acid salts of formula (I) which have differing values for R and/or M, and then heating the intimate salt mixture at temperatures of about 200° C. or higher for about 0.01 hour to about 20 hours;

or
(iii) heating at temperatures of about 200° C. or higher for about 0.01 hour to about 20 hours two or more separate metal phosphonic acid salts of formula (I), which differ by having different values for R and/or M to form individual flame retardant materials that are subsequently mixed together to form a blended flame retardant material.

3. The flame retardant epoxy resin composition according to claim 1 wherein M in formula (I) is Li, K, Na, Mg, Ca, Ba, Zn, Zr, B, Al, Si, Ti, Sn or Sb.

4. The flame retardant epoxy resin composition according to claim 1 wherein M in formula (I) is Al or Ca.

5. The flame retardant epoxy resin composition according to claim 1 wherein in formula (I) R is unsubstituted C 1-6 alkyl, C 6 aryl, C 7-10 alkylaryl, or C 7-12 arylalkyl.

6. The flame retardant epoxy resin composition according to claim 1 further comprising d) one or more compounds selected from the group consisting of additional flame retardants, synergists and flame retardant adjuvants.

7. The flame retardant epoxy resin composition according to claim 1 wherein the curing agent comprises a phenolic cross linker, a diamine, a polyamine, a dicyandiamide or a substituted dicyandiamide.

8. The flame retardant epoxy resin composition according to claim 1 wherein the epoxy resin comprises an epoxy novolac resin and/or a novolac cross linker.

9. The flame retardant epoxy resin composition according to claim 1 further comprising one or more additional resin selected from the group consisting of cyanate resins, bismaleimide resins, polyimide resins, phenolic resins, furan resins, xylene formaldehyde resins, ketone formaldehyde resins, urea resins, melamine resins, aniline resins, alkyd resins, unsaturated polyester resins, diallyl phthalate resins, triallyl cyanate resins, triazine resins, polyurethane resins, polyolefin resins, polyphenylene ether resins, benzocyclobutene resins, benzoxazine resins and silicone resins.

10. A laminate comprising a cured flame retardant epoxy composition according to claim 1 .

Assignees

• Chemtura Corp

Inventors

• Timberlake Larry D
• Hanson Mark V

Classifications

• C08J5/124

  using adhesives based on a macromolecular component · CPC title

• C08J2363/00

  Characterised by the use of epoxy resins; Derivatives of epoxy resins · CPC title

• H05K3/4626

  characterised by the insulating layers or materials (H05K3/4688 takes precedence) · CPC title

• B32B27/06 Primary

  as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} · CPC title

• C08J5/10

  characterised by the additives used in the polymer mixture · CPC title