Flame-retardant polyamide compositions

Abstract

A flame-retardant polyamide composition is described which has good arc tracking resistance. The composition is comprised of a polyamide, a selected organic flame-retardant, melamine or derivative, zinc borate or oxide and glass fiber.

Description

FIELD OF THE INVENTION

This invention relates to flame-retardant polyamide compositions, and, more particularly, to glass-reinforced, flame-retardant polyamide compositions having good arc tracking resistance.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 4,105,621 to Maslen et al. (ICI) described glass-reinforced, flame-retardant polyamide molding compositions that are resistant to arcing, i.e., to carbonization during electrical discharge, that occurs through leaking of electrical current. The patent states that one component, zinc borate, should be present in an amount of at least 5% by weight and preferably at least 7% (See column 2, lines 7-26), and also states that 5-30% of a halogenated flame retardant should be present.

It is desirable to reduce the amount of organic halogenated flame retardant and inorganic zinc borate in the composition without impairing arc tracking resistance. Organic halogenated materials are known to give off corrosive gaseous decomposition products during processing, and zinc borate detrimentally affects properties.

SUMMARY OF THE INVENTION

It has now been found that the amount of halogenated organic flame retardant and zinc borate present can be reduced if melamine or a selected derivative thereof is present in the composition. In addition, presence of melamine permits replacement of zinc borate with zinc oxide.

Specifically, the composition of this invention is a reinforced, flame-retardant, arc track resistant composition consisting essentially of

(a) 40-65 weight percent of composition of a polyamide of film-forming molecular weight, (b) 16-35 weight percent of composition of melamine, melam, melamine cyanurate or a melamine derivative, (c) 1-7 weight percent of composition selected from the class consisting of a chlorinated compound obtained from condensation of two moles of perchlorocyclopentadiene and one mole of 1,5-cyclooctadiene, or a brominated polystyrene. (d) 1-4.9 weight percent of composition of zinc borate or zinc oxide (e) 5-30 weight percent of composition of glass fibers, the percent amounts of components (a) through (e) totaling 100% with respect to one another.

DESCRIPTION OF THE INVENTION

The polyamides useful herein are well known in the art. They are thermoplastic, and are of film-forming molecular weight, i.e., have a number average molecular weight over 5000. The polyamide resin can be produced by condensation of equimolar amounts of a saturated organic dicarboxylic acid containing from 4-12 carbon atoms with an organic diamine containing 2-13 carbon atoms, in which the diamine can be employed, if desired, to provide an excess of amine end groups over carboxyl end groups in the polyamide. Vice versa, the diacid can be used to provide an excess of acid groups. Equally well, these polyamides may be made from acid-forming and amine-forming derivatives of said amines and acids such as esters, acid chlorides, amine salts, etc. Representative dicarboxylic acids used to make the polyamides include adipic acid, pimelic acid, suberic acid, sebacic acid, and dodecanedioic acid, while representative diamines include hexamethylenediamine and octamethylenediamine. In addition, the polyamide can also be prepared from self-condensation of a lactam. Examples of polyamides include polyhexamethylene adipamide (66 nylon), polyhexamethylene azelaamide (69 nylon), polyhexamethylene sebacamide (610 nylon), and polyhexamethylene dodecanoamide (612 nylon), poly bis-(4-aminocyclohexyl)methane dodecanoamide, or the polyamides produced by ring opening of lactams; i.e., polycaprolactam, (6 nylon), polylauric lactam, or poly-11-aminoundecanoic acid. It is also possible to use polyamides prepared by the polymerization of at least two of the amines or acids used to prepare the above polymers, as for example, a polymer made of adipic acid, and isophthalic acid and hexamethylene diamine. Blends of polyamides, such as a mixture of 66 nylon and 6 nylon are also included. Preferably the condensation polyamide employed herein is polyhexamethylene adipamide (66 nylon), or a blend of polyhexamethylene adipamide (66 nylon) and polycaprolactam (6 nylon). The polyamide is present in an amount of between 40-65 percent, preferably 40-55 percent, based on the weight of components (a)-(e).

Melamine has the formula ##STR1## while melam has the formula ##STR2## and melamine cyanurate is prepared by reaction of melamine with cyanuric acid. Cyanuric acid has the formula ##STR3##

The melamine derivatives are represented by the formula ##STR4## where R and R.sup.1 may be same or different and represent hydrogen, lower alkyl (alkyl of 1-6 carbons), phenyl, tolyl or halo-phenyl, provided that not all the R and R.sup.1 can be hydrogen.

These melamine compounds are present in an amount of 16-35 percent, preferably 20-29 percent, based on weight of components (a)-(e).

The chlorine-containing flame retardant is represented by the formula ##STR5##

The brominated polystyrene should contain at least 40% bromine by weight preferably at least 60% bromine and should have a molecular weight of at least 5000. These flame retardants are present in an amount of 1-7 percent, preferably 2-5 percent, based on weight of components (a)-(e). If more than 7% is present arc track resistance of the composition begins to decrease.

The zinc borate should be stable at the processing temperature, i.e., molding temperature, of the polyamide. By stable is meant that evolution of volatiles is not significant. The preferred form of zinc borate is of the form 2ZnO.3B.sub.2 O.sub.3 xH.sub.2 O, where x is between 3.3 and 3.7. This material does not tend to lose water below 300.degree. C. The higher hydrates for example 2ZnO.3B.sub.2 O.sub.3.7H.sub.2 O and 2ZnO.3B.sub.2 O.sub.3.9H.sub.2 O, lose water below the processing temperatures of most polyamides and are therefore preferably used with low melting point polyamides. Anhydrous zinc borate may be used if desired. The zinc borate or zinc oxide is present in an amount of 1-4.9 percent, preferably 2-4 percent, based on weight of compounds (a)-(e).

The glass fibers employed may be any commercially available glass fiber used for plastic molding resin reinforcement. The glass fiber can be present in an amount of 5-30 percent, preferably 15-25 percent, based on weight of components (a)-(e).

The effect of the presence of melamine or its derivatives is two-fold. It aids in improving arc tracking resistance while aiding in maintaining good flame retardancy, and it permits less zinc borate or oxide and less halogenated flame retardant to be present.

The compositions of the invention are conveniently made by mechanically blending the polyamide, the glass fibers, the halogen-containing flame retardant, the melamine, and the zinc borate or oxide. One method of obtaining an intimate blend of the composition in granule form involves the use of a screw extruder to intimately mix the mechanical blend in molten polyamide, subsequently extruding the mixture and chopping the extrudate into granule form. The ingredients fed to the extruder may consist of a simple tumbled blend of the ingredients or the components may be individually metered to the extruder. When using the preferred hydrated form of zinc borate care should be taken to reduce shear heating in the extruder to a minimum to avoid decomposition of the hydrate.

The compositions of the invention may include various other additives such as pigments, dyes, antioxidants, light and heat stabilizers and nucleating agents. It should be noted that these ingredients, particularly pigments, may have some effect on the specified properties, particularly arc tracking resistance, and it may be necessary to carry out some slight adjustment of the active ingredient concentration in the composition to compensate for such change. Lubricants which improve the ease of dispersion of the ingredients in the polyamide and release of fabricated articles from the molds may also be included. In addition solid lubricants which reduce wear on the fabricated articles in service may also be included. These include graphite and molybdenum disulphide.

Antimony oxide may be used, if desired, to enhance the effectiveness of the flame retardant. However, it tends to adversely affect the arc tracking resistance, but if used in amounts of less than 1 percent based on composition, antimony oxide may be present.

The compositions of the invention are normally prepared in a granular form for use in molding processes. Such granules are used for fabricating high strength articles with a high level of tracking resistance such as terminal blocks, switches and similar insulating parts in transformers and other electrical equipment and appliances.

The fire-retardant characteristics of the composition of the invention are determined using the Underwriters Laboratories Test Standard UL94. Using the Vertical Burning Test of this Standard the compositions of the invention should have a rating of 94VI or better when tested on samples having a thickness of 1/6 inch both when conditioned at a relative humidity of 50% for 48 hours or at 70.degree. C. for 1 week.

The arc tracking resistance of the compositions is determined by the method set out in Underwriters Laboratories 746 (UL-746). The compositions when tested according to this method should have a comparative tracking resistance of at least 340 volts, and more desirably at least 400.

Tensile strength and elongation were determined as described in ASTM D-638.

Notched Izod was measured by the procedure described in ASTM D-256-73.

Flexural modulus was determined by ASTM D-790.

EXAMPLES AND CONTROLS

The examples and controls below were prepared using a 21/2" single screw extruder with vented barrel. The polyamides and flame-retardant additives were mixed intimately in a suitable vessel followed by tumbling with the glass fibers. The mixture was melt blended in the extruder at between 260.degree.-290.degree. C. The melt temperature must be kept as low as possible to avoid possible decomposition of the additives. Normally the range 260.degree.-280.degree. C. is preferred. In a few instances a nylon concentrate containing 45% melamine was pre-extruded. This was then mixed with glass fibers and other additives in a subsequent extrusion.

The material exiting the die was quenched in water, cut into pellets, and sparged with nitrogen gas until cold to remove moisture.

The dried material was molded into test specimens using a 5- or 6-oz. screw injection molding machine.

All percentages are by weight.

The tables below set forth compositions and properties for various control and Examples of this invention and discuss their relationship.

The polyamide employed was nylon 66/6 (90/10) copolymer having a film-forming molecular weight.

The glass fibers employed were 3/16 inch long and had an aspect ratio of about 536.

The flame retardants employed are denoted as follows.

FR-1 is ##STR6##

DBBE is decabromobiphenyl ether.

FR-2 is brominated polystyrene with a weight average molecular weight of about 135,000.

The number of seconds in parenthesis in the Tables below indicate the afterburn times.

TABLE 1______________________________________COMPOSITION Polyamide Glass Fiber Melamine FR-1Control % % % %______________________________________A 55 25 20 --B 50 25 25 --C 45 25 30 --D 50 17 27 6E 48 15 33 4______________________________________PROPERTIES %UL Flammability(1/16") Tens. Str. Elon-Control 48/23/50 168/70 K Psi M Pa gation______________________________________A V2(73 sec) V2(59 sec) 21.7 149.6 3.0B V2(48 sec) V2(18 sec) 20.3 140.0 2.9C V2(53 sec) V2(19 sec) 19.3 133.1 2.6D V2(11 sec) VO(6 sec) 15.4 106.2 2.6E V2(7 sec) VO(0 sec) 12.5 86.2 2.3______________________________________ Wet ArcFlexural Modulus Notched Izod TrackingControl K Psi M Pa ft-lb/in J/m Volts______________________________________A 1303 8984 1.89 100.9 >600B 1441 9936 1.83 97.7 >600C 1560 10756 1.82 97.2 >600D 1138 7847 1.07 57.1 320E 1167 8046 0.93 49.6 346______________________________________

Controls A, B and C show that even up to 30% melamine alone is not sufficiently effective to afford even a V-1 rating. The rating of V-2 indicates that these materials produce flaming drips on burning. The arc tracking resistances of A, B, C compositions are over 600 volts.

The effects of adding FR-1 on flammability and arc tracking resistance are illustrated by Controls D and E. Although there was a great improvement in flame resistance, some tendency to drip was still apparent. Arc tracking resistance decreased to 320 V with 6% FR-1 and 346 V with 4% FR-1. Thus, high levels of FR-1 are detrimental to arc tracking resistance.

TABLE 1______________________________________COMPOSITION Zinc Borate (ZB) or Zinc Polyamide Glass Fiber Melamine FR-1 OxideExample % % % % (ZnO)______________________________________1 50 20 27 2 1ZnO2 48 17 30 3 2ZnO3 48 15 33 3 1ZnO4 48 17 30 3 2ZB5 50 25 20 3 2ZB6 45 25 25 3 2ZB7 45 23 27 3 2ZB8 49 25 16 6 4ZB9 47 25 18 6 4ZB10 49 25 18 4 4ZB11 47 25 20 4 4ZB12 47 25 20 5 3ZB13 45 25 25 3 2ZB______________________________________PROPERTIES %UL Flammability(1/16") Tens. Str. Elon-Example 48/23/50 168/70 K Psi M Pa gation______________________________________1 VO(42 sec) VI(41 sec) 15.0 103.4 2.02 VO(5 sec) VO(9 sec) 13.2 91.0 1.83 VO(7 sec) VO(3 sec) 12.5 86.2 1.84 VO(17 sec) VO(17 sec) 13.1 90.3 1.85 VI(73 sec) VI(59 sec) 17.4 120.0 2.36 VO(19 sec) VO(19 sec) 16.3 112.4 1.87 VO(18 sec) VO(10 sec) 16.1 111.0 1.88 VI(90 sec) VI(54 sec) 19.2 132.4 2.29 VO(37 sec) VI(37 sec) 19.3 133.1 2.210 VI(87 sec) VI(108 sec) 19.3 133.1 2.111 VI(96 sec) VI(37 sec) 19.2 132.4 2.212 VO(23 sec) VO(23 sec) 18.6 128.2 2.113 VI(55 sec) VO(21 sec) 19.1 131.7 2.2______________________________________ Wet ArcFlexural Modulus Notched Izod TrackingExample K Psi M Pa ft-lb/in J/m Volts______________________________________1 1265 8722 1.00 53.4 4262 1177 8115 0.79 42.1 4203 1168 8053 0.69 36.8 5114 1192 8219 0.70 37.4 4355 1330 9170 1.22 65.1 4306 1441 9936 1.29 68.9 4507 1469 10129 1.31 69.9 4408 1377 9494 1.46 77.9 4439 1495 10308 1.44 76.9 41710 1417 9770 1.45 77.4 400-44011 1389 9577 1.38 73.7 44212 1452 10012 1.43 76.3 45113 1486 10246 1.50 80.1 503______________________________________

The use of small amounts of zinc oxide or zinc borate prevents formation of flaming drips as shown by Examples 1 through 13. The lower amounts of FR-1 (2% to 6%) afforded arc tracking resistance greater than 400 volts.

Examples 5 through 7 explore the effect of melamine level at constant levels of FR-1 (3%) and zinc borate (2%). A V-0 rating was obtained with 25% melamine and arc tracking resistance of greater than 435 V.

Examples 8 through 13 show in more detail the effects of melamine, FR-1, and zinc borate on flammability and arc resistance. To obtain V-0 rating at least 20% melamine is required at 5% FR-1 and 3% zinc borate. It is apparent that lesser amounts of melamine are required with higher levels of FR-1 and zinc borate.

TABLE III______________________________________COMPOSITION Glass Polyamide Fiber ZincControl % % Melamine DBBE Borate______________________________________F 44 25 25 4 2G 45 27 18 6 4H 46 30 14 6 4______________________________________PROPERTIES %UL Flammability(1/16") Tens. Str. Elon-Control 48/23/50 168/70 K Psi M Pa gation______________________________________F VO(24 sec) VI(25 sec) 16.4 113.1 1.5G VO(31 sec) VI(36 sec) 18.7 128.9 1.8H V1(104 sec) VI(119 sec) 21.2 146.2 1.8______________________________________ Wet ArcFlexural Modulus Notched Izod TrackingControl K Psi M Pa ft-lb/in J/m Volts______________________________________F 1430 9860 1.10 58.7 250-300 scatterG 1483 10225 1.22 65.1 scatterH 1579 10887 1.32 70.5 280-340 scatter______________________________________

The effect of replacing FR-1 with decabromobiphenyl ether (DBBE) is shown by Controls F, G and H. From the results it is seen that DBBE is less effective than FR-1 but more importantly the arc tracking resistances were low and values were erratic and scattered.

TABLE IV______________________________________COMPOSITIONSExample Glass Zincor Polyamide Fiber Melamine FR-1 BorateControl % % % % %______________________________________I 47 25 25 3 --J 48 25 25 -- 214 45 25 25 3 2______________________________________PROPERTIESExample %or UL Flammability(1/16") Tens. Str. Elon-Control 48/23/50 168/70 K Psi M Pa gation______________________________________I V2(82) V2(95) 19.8 136.5 2.5J V2(181) V2(156) 19.5 134.5 2.214 VO(15) VI(65) 18.8 129.6 2.2______________________________________Example Wet Arcor Flexural Modulus Notched Izod TrackingControl K Psi M Pa ft-lb/in J/m Volts______________________________________I 1436 9901 1.43 76.3 393J 1426 9832 1.43 76.3 >60014 1568 10811 1.51 80.6 520-540______________________________________

Control I with 25% melamine and 3% FR-1 was V-2 and had an arc tracking resistance of 393 V. Control J, containing 25% melamine and 2% zinc borate was V-2, however, the arc resistance was greater than 600 V. Example 14 containing 25% melamine, 3% FR-1, and 2% zinc borate was V-0/V-1 and had an arc resistance of 520-540 V. Controls I and J illustrate that to obtain the good flammability resistance the three components--melamine, FR-1 and zinc borate--must be present. The absence of one component results in poor flame resistance.

TABLE V______________________________________COMPOSITION Mela- Flame Anti- Poly- Glass mine Retar- Zinc mony amide Fiber Compound dant Borate oxideExample % % % % % %______________________________________15 45 25 25 mela- 3FR-1 2 -- mine cy- anurate16 48 20 25 mela- 4FR-1 3 -- mine17 47.3 20 25 mela- 5FR-1 3 0.7 mine18 46.3 20 25 mela- 5FR-1 3 0.7 mine______________________________________PROPERTIES %UL Flammability(1/16") Tens. Str. Elon-Example 48/23/50 168/70 K Psi M Pa gation______________________________________15 VO(6) VI(31) 16.9 116.5 2.016 VO(4) VO(18) 17.1 117.9 2.317 VO(4) VO(10) 16.9 116.5 2.118 VO(5) VO(19) 17.0 117.2 2.1______________________________________ Wet ArcFlexural Modulus Notched Izod TrackingExample K Psi M Pa ft-lb/in J/m Volts______________________________________15 1478 10191 1.40 74.7 54616 1361 9384 1.31 69.9 50117 1357 9357 1.35 72.1 41918 1381 9522 1.33 71.0 460-480______________________________________

Example 15 provides an Example using melamine cyanurate in place of melamine.

Examples 16 and 17 provide Examples using antimony oxide (Sb.sub.2 O.sub.3); while Example 18 employs brominated polystyrene as the organic flame retardant.

Claims

1. A reinforced, flame-retardant, arc track resistant composition consisting of

(a) 40-65 weight percent of composition of a polyamide of film-forming molecular weight,

(b) 16-35 weight percent of composition of melamine, melam, melamine cyanurate or a melamine derivative represented by the formula ##STR7## where R and R.sup.1 may be the same or different and represent hydrogen, lower alkyl (alkyl of 1-6 carbons), phenyl, tolyl or halo-phenyl, provided that not all the R and R.sup.1 groups can be hydrogen,

(c) 1-7 weight percent of composition selected from the class consisting of a chlorinated compound obtained from condensation of two moles of perchlorocyclopentadiene and one mole of 1,5-cyclooctadiene, or a brominated polystyrene.

(d) 1-4.9 weight percent of composition of zinc borate or zinc oxide

(e) 5-30 weight percent of composition of glass fibers,

the percent amounts of components (a) through (e) totaling 100% with respect to one another.

2. The composition of claim 1 wherein component (b) is melamine.

3. The composition of claim 1 wherein component (c) is the chlorinated compound obtained from condensation of two moles of perchlorocyclopentadiene and one mole of 1,5-cyclooctadiene.

4. The composition of claim 1 wherein component (d) is zinc borate.

5. The composition of claim 3 or 4 wherein component (b) is melamine.

6. The composition of claims 2 or 4 wherein component (c) is the chlorinated compound obtained from condensation of two moles of perchlorocyclopentadiene and one mole of 1,5-cyclooctadiene.

7. The composition of claims 2 or 3 wherein component (d) is zinc borate.

8. The composition of claim 1 wherein component (b) is melamine (c) is the chlorinated compound obtained from condensation of two moles of perchlorocyclopentadiene and one mole of 1,5-cyclooctadiene, and (d) is zinc oxide.

9. The composition of claim 1, 2, 3 or 4 wherein component (c) is a brominated styrene.