Phosphorus containing flame retardants

Patent metadata

Field	Value
Publication number	US-9745449-B2
Application number	US-201414337500-A
Country	US
Kind code	B2
Filing date	Jul 22, 2014
Priority date	Jul 24, 2013
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

Abstract

Certain phosphonic acid salts heated at temperatures over 200° C. generate thermally stable, highly efficient flame retardant materials well suited for use as flame retardant additives in polymers. The flame retardants of the invention can be used as the sole flame retardant in a composition or in combination with other flame retardants, synergists or adjuvants.

First claim

What is claimed:

1. A moldable thermoplastic flame retardant polymer composition comprising:
a) a thermoplastic polymer, into which thermoplastic polymer has been compounded by melt processing without negatively impacting the physical, thermoplastic properties of the thermoplastic polymer,
b) from 1% to 50%, by weight based on the total weight of the flame retardant polymer composition, of a flame retardant material, wherein said flame retardant material is a product of thermal conversion, before compounding into the thermoplastic polymer, of one or more compounds of formula (I) into a different chemical species having greater thermal stability than the one or more compounds of formula (I) as determined by differential scanning calorimetry or weight loss data obtained while increasing temperatures during thermal analysis, which product is obtained by a process comprising heating in the absence of other components at temperatures of higher than 200° C. 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 7-18 alkylaryl, or C 7-18 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 to form the flame retardant material.

2. The moldable thermoplastic flame retardant polymer 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.

3. The moldable thermoplastic flame retardant polymer composition according to claim 1 wherein M in formula (I) is Al or Ca.

4. The moldable thermoplastic flame retardant polymer 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.

5. The moldable thermoplastic flame retardant polymer composition according to claim 4 wherein R is methyl, ethyl, propyl, or isopropyl.

6. The moldable thermoplastic flame retardant polymer composition according to claim 5 wherein M in formula (I) is Al or Ca.

7. The moldable thermoplastic flame retardant polymer composition according to claim 6 wherein the thermoplastic polymer comprises one or more of a polyolefin homopolymer, polyolefin copolymer, rubber, polyester, polyurethane, polysulfone, polyimide, polyphenylene ether, styrenic polymer, styrenic copolymer, polycarbonate, acrylic polymer, polyamide, polyacetal, or a blend thereof.

8. The moldable thermoplastic flame retardant polymer composition according to claim 7 wherein the thermoplastic polymer comprises one or more of a styrenic polymer, polyolefin, polyester, polycarbonate, polyamide, or polyurethane.

9. The moldable thermoplastic flame retardant polymer composition according to claim 8 wherein the thermoplastic polymer comprises a polyalkylene terephthalate, HIPS, or polyamide, which thermoplastic polymer optionally further comprises a reinforcing agent.

10. The moldable thermoplastic flame retardant polymer composition according to claim 9 wherein the thermoplastic polymer comprises polybutylene terephthalate, polyethylene terephthalate, glass filled polybutylene terephthalate, glass filled polyethylene terephthalate, polyamide or a glass filled polyamide.

11. The moldable thermoplastic flame retardant polymer composition according to claim 10 wherein the polyamide or glass filled polyamide comprises nylon 46, nylon 4T, nylon 6T/66 copolymer, or nylon 9T.

12. The moldable thermoplastic flame retardant polymer composition according to claim 7 wherein the thermoplastic polymer further comprises a reinforcing agent.

13. The moldable thermoplastic flame retardant polymer composition according to claim 7 further comprising (c) one or more compounds selected from the group consisting of additional flame retardant, synergist and flame retardant adjuvant.

14. The moldable thermoplastic flame retardant polymer composition according to claim 13 wherein the one or more compounds selected from the group consisting of additional flame retardants, synergists and flame retardant adjuvants comprises an aluminum tris(dialkylphosphinate), aluminum hydrogen phosphite, a methylene-diphenylphosphine oxide-substituted polyaryl ether, a xylylenebis(diphenylphosphine oxide), 1,2-bis-(9,10-dihydro-9-oxy-10-phosphaphenanthrene-10-oxide)ethane, a 4,4′-bis(diphenylphosphinylmethyl)-1,1′-biphenyl, melem, or dimelamine zinc pyrophosphate.

15. The moldable thermoplastic flame retardant polymer composition according to claim 1 wherein the thermoplastic polymer comprises one or more of a polyolefin homopolymer, polyolefin copolymer, rubber, polyester, polyurethane, polysulfone, polyimide, polyphenylene ether, styrenic polymer, styrenic copolymer, polycarbonate, acrylic polymer, polyamide, polyacetal, or a blend thereof.

16. The moldable thermoplastic flame retardant polymer composition according to claim 15 wherein the thermoplastic polymer comprises one or more of a styrenic polymer, polyolefin, polyester, polycarbonate, polyamide, or polyurethane.

17. The moldable thermoplastic flame retardant polymer composition according to claim 16 wherein the thermoplastic polymer comprises a polyalkylene terephthalate, HIPS, or polyamide, and wherein the thermoplastic polymer optionally further comprises a reinforcing agent.

18. The moldable thermoplastic flame retardant polymer composition according to claim 17 wherein the thermoplastic polymer comprises polybutylene terephthalate, polyethylene terephthalate, glass filled polybutylene terephthalate, glass filled polyethylene terephthalate, a polyamide or a glass filled polyamide.

19. The moldable thermoplastic flame retardant polymer composition according to claim 18 wherein the polyamide or glass filled polyamide comprises nylon 46, nylon 4T, nylon 6T/66 copolymer, or nylon 9T.

20. The moldable thermoplastic flame retardant polymer composition according to claim 15 wherein the thermoplastic polymer further comprises a reinforcing agent.

21. The moldable thermoplastic flame retardant polymer composition according to claim 1 wherein the thermoplastic polymer comprises one or more of a polyphenylene ether/styrenic resin blend, ABS, polyvinyl chloride/ABS blend, methacrylonitrile containing ABS, α-methylstyrene containing ABS, polyester/ABS, polycarbonate/ABS, impact modified polyester or impact modified polystyrene.

22. The moldable thermoplastic flame retardant polymer composition according to claim 1 further comprising (c) one or more compounds selected from the group consisting of additional flame retardants, synergists and flame retardant adjuvants.

23. The moldable thermoplastic flame retardant polymer composition according to claim 22 , wherein the one or more compounds selected from the group consisting of additional flame retardants, synergists and flame retardant adjuvants comprise halogenated flame retardants, alkyl or aryl phosphine oxide flame retardants, alkyl or aryl phosphate flame retardants, alkyl or aryl phosphonates, alkyl or aryl alkylphosphinates, or salts of alkyl or aryl phosphinic acid.

24. The

Assignees

• Chemtura Corp
• Lanxess Solutions Us Inc

Inventors

• Stockdale Zachary D
• Hanson Mark V
• Timberlake Larry D
• Narayan Subramaniam
• Fielding William R

Classifications

• C07F9/5333

  Arylalkane phosphine oxides or thioxides (C07F9/5329 takes precedence) · CPC title

• C08K5/34928

  Salts · CPC title

• C07F9/657172

  the ring phosphorus atom and one oxygen atom being part of a (thio)phosphinic acid ester: [IMAGE cpc-sch-C07F-1008.gif] (X = O, S) · CPC title

• C07F9/3839 Primary

  Polyphosphonic acids · CPC title

• C08K5/5333

  Esters of phosphonic acids · CPC title