Halogen-free flame retardant TPU with very high LOI

Patent metadata

Field	Value
Publication number	US-9920166-B2
Application number	US-201314406902-A
Country	US
Kind code	B2
Filing date	Jun 5, 2013
Priority date	Jun 18, 2012
Publication date	Mar 20, 2018
Grant date	Mar 20, 2018

Abstract

The present invention relates to flame retardant thermoplastic polyurethane (TPU) compositions, and more particularly to flame retardant thermoplastic polyurethane compositions comprising non-halogen flame retardants. The TPU compositions are useful for applications where high flame performance, and optionally low smoke properties, as well as high tensile strength are desirable, such as wire and cable applications, film applications, molding applications, and the like. This invention also relates to processes to produce the non-halogen flame retardant TPU compositions and processes to produce wire and cable jacketing from such compositions.

First claim

What is claimed is:

1. A flame retardant thermoplastic polyurethane composition comprising:
(a) 44.7% to 50.7% by weight of a thermoplastic polycarbonate polyurethane resin, wherein the thermoplastic polycarbonate polyurethane resin consists of aromatic polycarbonate thermoplastic polyurethane resin;
(b) 7% by weight of an aromatic phosphate;
(c) 37% to 46% by weight a phosphate salt;
wherein (a), the thermoplastic polycarbonate polyurethane resin, (b), the aromatic phosphate, and (c), the phosphate salt, are each halogen-free.

2. The flame retardant thermoplastic polyurethane composition of claim 1 , further comprising: (d) a boron phosphate, a magnesium oxide, a dipentaerythritol, a polytetrafluoroethylene polymer, or any combination thereof.

3. The flame retardant thermoplastic polyurethane composition of claim 1 wherein (b), the aromatic phosphate, comprises one or more compounds represented by formula (I), formula (II), formula (III), or combinations thereof:

wherein: each R 1 is independently a hydrocarbon group or a hydrocarbonoxy group; R 3 is a hydrocarbylene group; each R 2 is independently a hydrocarbon group or a hydrocarbonoxy group; and m and n are integers from 1 to 30.

4. The flame retardant thermoplastic polyurethane composition of claim 3 wherein component (b), the aromatic phosphate, comprises one or more compounds represented by formula (II) where n is 1 and each R 1 and R 2 is a hydrocarbon group containing an aromatic ring or a hydrocarbonoxy group containing an aromatic ring.

5. The flame retardant thermoplastic polyurethane composition of claim 1 wherein (b), the aromatic phosphate, comprises bisphenol A diphosphate.

6. The flame retardant thermoplastic polyurethane composition of claim 1 wherein (c), the phosphate salt, comprises amine phosphate, melamine phosphate, dimelamine phosphate, melamine pyrophosphate, dimelamine pyrophosphate, ammonium polyphosphate, melamine polyphosphate, ethylenediamine phosphate, melamine nitrilotrisphosphonate or a combination thereof.

7. The flame retardant thermoplastic polyurethane composition of claim 1 wherein (c), the phosphate salt, comprises a polyphosphoric acid ammonium salt, a polyphosphoric acid melamine salt, or a combination thereof, and wherein the composition further comprises zinc oxide.

8. The flame retardant thermoplastic polyurethane composition of claim 1 wherein:
(b), the aromatic phosphate, comprises bisphenol A diphosphate; and
(c), the phosphate salt, comprises a polyphosphoric acid ammonium salt, a polyphosphoric acid melamine salt, or a combination thereof, where the composition further comprises zinc oxide.

9. A method of increasing the Limiting Oxygen Index (LOI) of a flame retardant thermoplastic polycarbonate polyurethane composition comprising the steps of:
(1) adding to a thermoplastic polycarbonate polyurethane resin, wherein the thermoplastic polycarbonate polyurethane resin consists of an aromatic polycarbonate polyurethane resin, an aromatic phosphate flame retardant and a phosphate salt flame retardant;
wherein the thermoplastic polycarbonate polyurethane resin, the aromatic phosphate flame retardant, and the phosphate salt flame retardant, are each halogen-free;
resulting in a thermoplastic polycarbonate polyurethane composition with a LOI higher than that of the thermoplastic polyurethane resin, wherein the composition comprises 44.7% to 50.7% by weight of an aromatic polycarbonate thermoplastic polyurethane resin; 7% by weight of an aromatic phosphate; and 37% to 46% by weight a phosphate salt.

10. A method of making a high LOI thermoplastic polyurethane composition comprising the steps of mixing:
(a) 44.7% to 50.7% by weight of a thermoplastic polycarbonate polyurethane resin, wherein the thermoplastic polycarbonate polyurethane resin consists of an aromatic polycarbonate thermoplastic polyurethane resin;
(b) 7% by weight of an aromatic phosphate; and
(c) 37% to 46% by weight of a phosphate salt;
wherein the thermoplastic polycarbonate polyurethane resin, the aromatic phosphate flame retardant, and the phosphate salt flame retardant, are each halogen-free.

Assignees

• Lubrizol Advanced Mat Inc

Inventors

• Makadia Chetan M
• Giovannitti-Jensen Ann

Classifications

• H01B3/307

  Other macromolecular compounds · CPC title

• C08K5/49

  Phosphorus-containing compounds {(C08K5/0091 takes precedence)} · CPC title

• C08K3/32 Primary

  Phosphorus-containing compounds · CPC title

• C08G18/44

  Polycarbonates · CPC title

• C08K5/0066

  Flame-proofing or flame-retarding additives · CPC title