Patent Application
20140316032
The present invention relates to the use of aromatic P—N-compounds in flame retardant polymer compositions. These compositions are especially useful for the manufacture of flame retardant compositions based on thermoplastic polymers, especially polyolefin homo- and copolymers, polycondensates, such as polyamines or polyesters and duroplastic polymers, such as polyepoxides.
Flame retardants are added to polymeric materials (synthetic or natural) to enhance the flame retardant properties of the polymers. Depending on their composition, flame retardants may act in the solid, liquid or gas phase either chemically, e.g. as a spumescent by liberation of nitrogen, and/or physically, e.g. by producing a foam coverage. Flame retardants interfere during a particular stage of the combustion process, e.g. during heating, decomposition, ignition or flame spread.
There is still a need for flame retardant compositions with improved properties that can be used in different polymer substrates. Increased standards with regard to safety and environmental requirements result in stricter regulations. Particularly known halogen containing flame retardants no longer match all necessary requirements. Therefore, halogen free flame retardants are preferred, particularly in view of their better performance in terms of smoke density associated with fire. Improved thermal stability and less corrosive behaviour of smoke evolved from fire are further benefits of halogen free flame retardant compositions.
Phosphaphenanthrene amides with trivalent phosphorus and thermoplastic polymer compositions are known from U.S. Pat. No. 4,380,515 as stabilizers for thermoplastics and elastomers to protect these substrates from degradation caused by the action of oxygen, light and heat.
Phosphaphenanthrene amides with trivalent phosphorus and their use in emulsions as photographic development accelerators are also known from EP 56 787.
It has surprisingly been found that thermoplastic or duroplastic polymers with excellent flame retardant properties are prepared in the event that aromatic P—N-compounds are added to the polymer substrate. Moreover, flame dripping during the application of fire is significantly reduced.
These compositions have excellent thermal stability and are therefore especially suited for the application in engineering thermoplastics and epoxy laminates used e.g. for the manufacture of electrical and electronic parts and devices. Furthermore, epoxy resins comprising the inventive compounds show no or only a minor negative impact on the glass transition temperature, which is considered advantageous especially for their use in epoxy laminates for the manufacture of printed circuit boards. By using the instant flame retardant additives in thermoplastic and duroplastic resins, conventional halogen containing flame retardants and halogenated epoxy resins, antimony compounds, and inorganic fillers may largely be reduced or replaced.
The invention relates to the use of a P—N-compound of the formula
Wherein
n represents zero or one;
X represents oxygen or sulphur;
represents oxygen or a direct bond between phosphorus and the phenyl group;
the dotted line between the phenyl groups represents a direct bond adjacent to
provided that
represents oxygen;
R represents hydrogen or a hydrocarbon radical selected from the group consisting of C1-C4alkyl, C5-C6cycloalkyl, (C1-C4alkyl)1-2C5-C6cycloalkyl, C6-C14aryl and C7-C15alkylaryl; or represents a group of the partial formula
Wherein
n represents zero or one;
X represents oxygen or sulphur;
represents oxygen or a direct bond between phosphorus and the phenyl group;
the dotted line between the phenyl groups represents a direct bond adjacent to
provided that
represents oxygen;
A represents C2-C6alkylene, a bivalent carbocyclic group selected from the group consisting of 1,2-, 1,3- or 1,4-phenylene, 2,4-, 2,5- or 2,6-tolylene, C5-C6-cycloalkylene, (C1-C4alkyl)1-2C5-C6-cycloalkylene,
or a group
and the dotted line to A represents the bond to the other nitrogen atom in formula I;
for inducing the flame retardancy in polymers.
The polymer compositions, wherein the compounds (I), as defined above are present, attain the desirable V-0 rating, according to UL-94 (Underwriter's Laboratories Subject 94) and other excellent ratings in related test methods, especially in glass fibre reinforced formulations where conventional FR systems tend to fail.
C1-C4alkyl is methyl, ethyl, n- or isopropyl, or n-, iso- or tert-butyl.
C5-C6cycloalkyl is cyclopentyl or cyclohexyl.
(C1-C4alkyl)1-2C5-C6cycloalkyl is, for example, cyclopentyl or cyclohexyl substituted by one or two of the above-mentioned C1-C4alkyl groups.
C6-C14aryl is, for example, phenyl or naphthyl, e.g. 1- or 2-naphthyl.
C7-C15alkylaryl is, for example, phenyl or naphthyl, e.g. 1- or 2-naphthyl, substituted by the above-mentioned C1-C4alkyl groups.
C2-C6alkylene is, for example, 1,2- or 1,3-propylene or 1,4-, 1,3- or 1,2-butylene or, preferably, ethylene.
C5-C6-cycloalkylene is, for example, 1,2- or 1,3-cyclopentylene or 1,2-, 1,3- or 1,4-cyclohexylene, or preferably 1,4-cyclohexylene.
(C1-C4alkyl)1-2C5-C6-cycloalkylene is, for example, 1-methyl or 1,1-dimethyl-2,4- or 2,6-cyclohexylene, such as
The bivalent groups
have the following preferred points of attachment:
A preferred group of P—N compounds (I) consists of 9,10-dihydro-9-oxa-10-phosphaphenan-threne-N-derivatives of the formula
Wherein
n represents zero or one;
X represents oxygen or sulphur;
R represents hydrogen, C1-C4alkyl, C6-C14aryl or C7-C15alkylaryl; or a group of the partial formula
Wherein
n represents zero or one;
X represents oxygen or sulphur;
A represents C2-C4alkylene, C5-C6-cycloalkylene, C1-C4alkyl-C5-C6-cycloalkylene, 1,2-, 1,3- or 1,4-phenylene, 2,4- or 2,6-tolylene or the group
and the dotted line represents the bond to the other nitrogen atom in formula IA.
Therefore, a preferred embodiment of the invention relates to the use of these compounds (IA) for inducing the flame retardancy in polymers.
These compounds (I) and (IA) are preferably contained in the flame retardant compositions according to the invention in an amount from 1.0-90.0 wt.-%, preferably 2.0-50.0 wt.-%, based on the weight of the polymer substrate.
The term polymer and substrate comprises within its scope duroplastic, thermoplastic polymers or thermosets.
A list of suitable thermoplastic polymers is given below:
Preferred are polycarbonates obtainable by reaction of a diphenol, such as bisphenol A, with a carbonate source. Examples of suitable diphenols are:
and 4,4′-(2-norbornylidene)-bis(2,6-dichlorophenol); or fluorene-9-bisphenol:
The carbonate source may be a carbonyl halide, a carbonate ester or a haloformate. Suitable carbonate halides are phosgene or carbonylbromide. Suitable carbonate esters are dialkylcarbonates, such as dimethyl- or diethylcarbonate, diphenyl carbonate, phenyl-alkyl-phenylcarbonate, such as phenyl-tolylcarbonate, dialkylcarbonates, such as dimethyl- or diethylcarbonate, di-(halophenyl)carbonates, such as di-(chlorophenyl)carbonate, di-(bromo-phenyl)carbonate, di-(trichlorophenyl)carbonate or di-(trichlorophenyl)carbonate, di-(alkyl-phenyl)carbonates, such as di-tolylcarbonate, naphthylcarbonate, dichloro-naphthylcarbonate and others.
The polymer substrate mentioned above, which comprises polycarbonates or polycarbonate blends is a polycarbonate-copolymer, wherein isophthalate/terephthalate-resorcinol segments are present. Such polycarbonates are commercially available, e.g. Lexan® SLX (General Electrics Co. USA). Other polymeric substrates of component b) may additionally contain in the form as admixtures or as copolymers a wide variety of synthetic polymers including polyolefins, polystyrenes, polyesters, polyethers, polyamides, poly(meth)acrylates, thermoplastic polyurethanes, polysulphones, polyacetals and PVC, including suitable compatibilizing agents. For example, the polymer substrate may additionally contain thermoplastic polymers selected from the group of resins consisting of polyolefins, thermoplastic polyurethanes, styrene polymers and copolymers thereof. Specific embodiments include polypropylene (PP), polyethylene (PE), polyamide (PA), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), glycol-modified polycyclohexylenemethylene terephthalate (PCTG), polysulphone (PSU), polymethylmethacrylate (PMMA), thermoplastic polyurethane (TPU), acrylonitrile-butadiene-styrene (ABS), acrylonitrile-styrene-acrylic ester (ASA), acrylonitrile-ethylene-propylene-styrene (AES), styrene-maleic anhydride (SMA) or high impact polystyrene (HIPS).
A preferred embodiment of the invention relates to the use of P—N-compounds (I) in thermoplastic polymers. Preferred thermoplastic polymers include polyamides, polyesters and polycarbonates.
Another preferred embodiment of the invention relates to composition, wherein component c) is a duroplastic polymer substrate of the polyepoxide type.
A preferred embodiment of the invention relates to a composition which comprises
A preferred embodiment of the invention relates to a composition, which comprises
Suitable polyfunctional epoxide compounds according to Component b) are epoxides, wherein at least two epoxy groups of the partial formula
are present, which are attached directly to carbon, oxygen, nitrogen or sulphur atoms, and wherein q represents zero, R1 and R3 both represent hydrogen and R2 represents hydrogen or methyl; or wherein q represents zero or 1, R1 and R3 together form the —CH2—CH2— or —CH2—CH2—CH2— groups and R2 represents hydrogen.
A suitable hardener compound according to Component c) is any of the known hardeners for epoxy resins, particularly the ones commercially available. The amine, phenolic and anhydride hardeners are particularly preferred, such as polyamines, e.g. ethylenediamine, diethylenetri-amine, triethylenetetramine, hexamethylenediamine, methanediamine, N-aminoethyl piperazine, diaminodiphenylmethane [DDM], alkyl-substituted derivatives of DDM, isophoronediamine [IPD], diaminodiphenylsulphone [DDS], 4,4-methylenedianiline [MDA], or m-phenylenediamine [MPDA]), polyamides, alkyl/alkenyl imidazoles, dicyanodiamide [DICY], 1,6-hexamethylene-bis-cyanoguanidine, phenolic hardeners such as phenol novolac and cresol novolac, or acid anhydrides, e.g. dodecenylsuccinic acid anhydride, hexahydrophthalic acid anhydride, tetrahydro-phthalic acid anhydride, phthalic acid anhydride, pyromellitic acid anhydride, styrene-maleic acid anhydride copolymers, and derivatives thereof.
A preferred embodiment of the invention relates to a composition, which comprises as component b) a polyfunctional epoxide compound and a hardener compound c) that contains at least two amino groups, such as dicyandiamide.
A further embodiment of the invention relates to a composition which comprises
a) A P—N-compound selected from the group consisting of
b) A polymer substrate.
The instant invention further pertains to the use of compounds (I) in flame retardant compositions which comprise, in addition to the components defined above, optional components, such as additional flame retardants and/or further additives selected from the group consisting of tetraalkylpiperidine additives, polymer stabilizers, fillers, reinforcing agents and so-called anti-dripping agents that reduce the melt flow of thermoplastic polymers and reduce the formation of drops at higher temperatures.
A further embodiment of the invention relates to a process for inducing the flame retardancy in polymers, which comprises adding to a polymer substrate a combination of at least one P—N-compound of the formula
Wherein
n represents zero or one;
X represents oxygen or sulphur;
represents oxygen or a direct bond between phosphorus and the phenyl group;
the dotted line between the phenyl groups represents a direct bond adjacent to
provided that
represents oxygen;
R represents hydrogen or a hydrocarbon radical selected from the group consisting of C1-C4alkyl, C5-C6cycloalkyl, (C1-C4alkyl)1-2-C5-C6cycloalkyl, C6-C14aryl and C7-C15alkylaryl;
or represents a group of the partial formula
Wherein
n represents zero or one;
X represents oxygen or sulphur;
represents oxygen or a direct bond between phosphorus and the phenyl group;
the dotted line between the phenyl groups represents a direct bond adjacent to
provided that
represents oxygen;
A represents C2-C4alkylene or a bivalent carbocyclic group selected from the group consisting of 1,2-, 1,3- or 1,4-phenylene, 2,4-, 2,5- or 2,6-tolylene, C5-C6-cycloalkylene, (C1-C4alkyl)1-2C5-C6-cycloalkylene,
or a group
and the dotted line to A represents the bond to the other nitrogen atom in formula I;
with at least one additional flame retardant.
Such additional flame retardants are for example selected from the group consisting of phosphorus and/or nitrogen generating flame retardants, organohalogen containing flame retardants and inorganic flame retardants. Phosphorus containing flame retardants are, for example, tetra-phenyl resorcinol diphosphate, resorcinol phenylphosphate oligomer (Fyrolflex® RDP, Akzo No-bel), triphenyl phosphate, bisphenol A phenylphosphate oligomer (Fyrolflex® BDP), tris(2,4-di-tert-butylphenyl)phosphate, ethylenediamine diphosphate (EDAP), tetra(2,6-dimethylphenyl) resorcinol diphosphate, ammonium polyphosphate, diethyl-N,N-bis(2-hydroxyethyl)-amino-methyl phosphonate, hydroxyalkyl esters of phosphorus acids, salts of di-C1-C4alkylphosphinic acids and of hypophosphoric acid (H3PO2), particularly the Ca2+, Zn2+, or Al3+ salts, tetrakis(hydroxymethyl)phosphonium sulphide, triphenylphosphine, triphenyl phosphine oxide, tetraphenyldiphosphine monoxide, phosphazenes and 9,10-dihydro-9-oxa-10-phosphorylphenanthrene-10-oxide (DOPO) and its derivatives, such as 2-(9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide)-1,4-benzenediol.
Nitrogen generating flame retardants are, for example, isocyanurate flame retardants, such as polyisocyanurate, esters of isocyanuric acid or isocyanurates. Representative examples are hydroxyalkyl isocyanurates, such as tris-(2-hydroxyethyl)isocyanurate, tris(hydroxymethyl)-isocyanurate, tris(3-hydroxy-n-propyl)isocyanurate or triglycidyl isocyanurate.
Nitrogen containing flame-retardants include further melamine-based flame-retardants. Representative examples are: melamine cyanurate, melamine borate, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, melamine ammonium polyphosphate, melamine ammonium pyrophosphate, dimelamine phosphate and dimelamine pyrophosphate.
Further examples are: benzoguanamine, allantoin, glycoluril, urea cyanurate, ammonium polyphosphate, and a condensation product of melamine from the series melem, melam, melon and/or a higher condensed compound or a reaction product of melamine with phosphoric acid or a mixture thereof.
Representative organohalogen flame retardants are, for example:
Polybrominated diphenyl oxide (DE-60F, Great Lakes Corp.), decabromodiphenyl oxide (DBDPO; Saytex® 102E), tris[3-bromo-2,2-bis(bromomethyl)propyl]phosphate (PB 370®, FMC Corp.), tris(2,3-dibromopropyl)phosphate, tris(2,3-dichloropropyl)phosphate, chlorendic acid, tetrachlorophthalic acid, tetrabromophthalic acid, polychloroethyl triphosphonate mixture, tetra-bromobisphenol A bis(2,3-dibromopropyl ether) (PE68), brominated epoxy resin, ethylene-bis(tetrabromophthalimide) (Saytex® BT-93), bis(hexachlorocyclopentadieno)cyclooctane (Declorane Plus®), chlorinated paraffins, octabromodiphenyl ether, 1,2-bis(tribromophenoxy)-ethane (FF680), tetrabromo-bisphenol A (Saytex® RB100), ethylene bis-(dibromo-norbornanedicarboximide) (Saytex® BN-451), bis-(hexachlorocyclopentadieno)cyclooctane, PTFE, tris-(2,3-dibromopropyl)-isocyanurate, and ethylene-bis-tetrabromophthalimide.
The organohalogen flame retardants mentioned above are routinely combined with an inorganic oxide synergist. Most common for this use are zinc or antimony oxides, e.g. Sb2O3 or Sb2O5. Boron compounds are suitable, too.
Representative inorganic flame retardants include, for example, aluminium trihydroxide (ATH), boehmite (AlOOH), magnesium dihydroxide (MDH), hydrotalcite, zinc borates, CaCO3, (organically modified) layered silicates, (organically modified) layered double hydroxides, zeolites and mixtures thereof.
Particularly preferred as additional flame retardant are nitrogen generating compounds selected from the group consisting of melamine cyanurate, melamine polyphosphate, ammonium polyphosphate, melamine ammonium phosphate, melamine ammonium polyphosphate, melamine ammonium pyrophosphate, a condensation product of melamine with phosphoric acid and other reaction products of melamine with phosphoric acid and mixtures thereof.
Highly preferred as an additional flame retardant is a phosphorus containing flame retardant selected from the group consisting of tetra(2,6-dimethylphenyl)resorcinol diphosphate, salts of di-C1-C4alkylphosphinic acid, salts of hypophosphoric acid and 9,10-dihydro-9-oxa-10-phosphorylphenanthrene-10-oxide (DOPO) and its derivatives.
The above-mentioned additional flame retardant classes are advantageously contained in the composition of the invention in an amount from about 0.5% to about 40.0% by weight of the organic polymer substrate; for instance about 1.0% to about 30.0%; for example about 2.0% to about 25.0% by weight based on the total weight of the composition.
In the process defined above, the weight ratio in the combination of the P—N-compound (I) and the additional flame retardant is preferably between 1:10 and 10:1.
The combination of the P—N-compound (I) and the additional flame retardant is preferably contained in the flame retardant compositions according to the process defined above in an amount from 0.5-60.0 wt.-%, preferably 2.0-55.0 wt.-%, based on the total weight of the composition.
According to another embodiment, the invention relates to compositions which additionally comprise as additional component so-called anti-dripping agents.
These anti-dripping agents reduce the melt flow of the thermoplastic polymer and inhibit the formation of drops at high temperatures. Various references, such as U.S. Pat. No. 4,263,201, describe the addition of anti-dripping agents to flame retardant compositions.
Suitable additives that inhibit the formation of drops at high temperatures include glass fibres, polytetrafluoroethylene (PTFE), high temperature elastomers, carbon fibres, glass spheres and the like.
The addition of polysiloxanes of different structures has been proposed in various references; cf. U.S. Pat. Nos. 6,660,787, 6,727,302 or 6,730,720.
According to a further embodiment, the invention relates to compositions which additionally comprise as additional components fillers and reinforcing agents. Suitable fillers are, for example, glass powder, glass microspheres, silica, mica and talcum.
Stabilizers are preferably halogen-free and selected from the group consisting of nitroxyl stabilizers, nitrone stabilizers, amine oxide stabilizers, benzofuranone stabilizers, phosphite and phosphonite stabilizers, quinone methide stabilizers and monoacrylate esters of 2,2′-alkylidenebisphenol stabilizers.
As mentioned above, the composition according to the invention may additionally contain one or more conventional additives, for example selected from pigments, dyes, plasticizers, antioxidants, thixotropic agents, levelling assistants, basic co-stabilizers, metal passivators, metal oxides, organophosphorus compounds, further light stabilizers and mixtures thereof, especially pigments, phenolic antioxidants, calcium stearate, zinc stearate, UV absorbers of the 2-hydroxy-benzophenone, 2-(2′-hydroxyphenyl)benzotriazole and/or 2-(2-hydroxyphenyl)-1,3,5-triazine groups.
Preferred additional additives for the compositions as defined above are processing stabilizers, such as the above-mentioned phosphites and phenolic antioxidants, and light stabilizers, such as benzotriazoles. Preferred specific antioxidants include octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate (IRGANOX 1076), pentaerythritol-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] (IRGANOX 1010), tris(3,5-di-tert-butyl-4-hydroxyphenyl)isocyanurate (IRGANOX 3114), 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene (IRGANOX 1330), triethyleneglycol-bis[3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate] (IRGANOX 245), and N,N′-hexane-1,6-diyl-bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionamide] (IRGANOX 1098). Specific processing stabilizers include tris(2,4-di-tert-butylphenyl)phosphite (IRGAFOS 168), 3,9-bis(2,4-di-tert-butylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane (IRGAFOS 126), 2,2′,2″-nitrilo[triethyl-tris(3,3′,5,5′-tetra-tert-butyl-1,1′-biphenyl-2,2′-diyl)]phosphite (IRGAFOS 12), and tetrakis(2,4-di-tert-butylphenyl)[1,1-biphenyl]-4,4′-diyl-bisphosphonite (IRGAFOS P-EPQ). Specific light stabilizers include 2-(2H-benzotriazole-2-yl)-4,6-bis(1-methyl-1-phenylethyl)phenol (TIN UVIN 234), 2-(5-chloro(2H)-benzotriazole-2-yl)-4-(methyl)-6-(tert-butyl)phenol (TINUVIN 326), 2-(2H-benzotriazole-2-yl)-4-(1,1,3,3-tetramethylbutyl)phenol (TINUVIN 329), 2-(2H-benzotriazole-2-yl)-4-(tert-butyl)-6-(sec-butyl)phenol (TINUVIN 350), 2,2′-methylenebis(6-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)phenol) (TINUVIN 360), and 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-[(hexyl)oxy]-phenol (TINUVIN 1577), 2-(2′-hydroxy-5′-methylphenyl)benzotriazole (TINUVIN P), 2-hydroxy-4-(octyloxy)benzophenone (CHIMASSORB 81), 1,3-bis-[(2′-cyano-3′,3′-diphenylacryloyl)oxy]-2,2-bis-{[(2′-cyano-3′,3′-diphenylacryloyl)oxy]methyl}-propane (UVINUL 3030, BASF), ethyl-2-cyano-3,3-diphenylacrylate (UVINUL 3035, BASF), and (2-ethylhexyl)-2-cyano-3,3-diphenylacrylate (UVINUL 3039, BASF).
According to a further embodiment the compositions comprise as an optional component the additional flame retardants defined above and additives selected from the group consisting of polymer stabilizers and tetraalkylpiperidine derivatives.
Representative examples of tetraalkylpiperidine derivatives are selected from the group consisting of
The oligomeric compound which is the condensation product of 4,4′-hexamethylene-bis(amino-2,2,6,6-tetramethylpiperidine) and 2,4-dichloro-6-[(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl)butylamino]-s-triazine end-capped with 2-chloro-4,6-bis(dibutyl-amino)-s-triazine,
The compound of the formula
and the compound of the formula
in which n is a numeral from 1 to 15.
The additives mentioned above are preferably contained in an amount of 0.01 to 10.0%, especially 0.05 to 5.0%, relative to the weight of the polymer substrate of Component c).
The incorporation of the components defined above into the polymer component is carried out by known methods such as dry blending in the form of a powder, or wet mixing in the form of solutions, dispersions or suspensions for example in an inert solvent, water or oil. The additive components may be incorporated, for example, before or after molding or also by applying the dissolved or dispersed additive or additive mixture to the polymer material, with or without subsequent evaporation of the solvent or the suspension/dispersion agent. They may be added directly into the processing apparatus (e.g. extruders, internal mixers, etc.), e.g. as a dry mixture or powder, or as a solution or dispersion or suspension or melt.
The addition of the additive components to the polymer substrate can be carried out in customary mixing machines in which the polymer is melted and mixed with the additives. Suitable machines are known to those skilled in the art. They are predominantly mixers, kneaders and extruders.
The process for incorporating the components defined above in the polymer substrate b) is preferably carried out in an extruder by introducing the additive during processing.
Particularly preferred processing machines are single-screw extruders, contra-rotating and co-rotating twin-screw extruders, planetary-gear extruders, ring extruders or co-kneaders. Processing machines provided with at least one gas removal compartment can be used to which a vacuum can be applied.
Suitable extruders and kneaders are described, for example, in Handbuch der Kunststoffex-trusion, Vol. 1 Grundlagen, Editors F. Hensen, W. Knappe, H. Potente, 1989, pp. 3-7, ISBN:3-446-14339-4 (Vol. 2 Extrusionsanlagen 1986, ISBN 3-446-14329-7).
For example, the screw length is 1-60 screw diameters, preferably 35-48 screw diameters. The rotational speed of the screw is preferably 10-600 rotations per minute (rpm), preferably 25-300 rpm.
The maximum throughput is dependent on the screw diameter, the rotational speed and the driving force. The process of the present invention can also be carried out at a level lower than maximum throughput by varying the parameters mentioned or employing weighing machines delivering dosage amounts.
If a plurality of components is added, these can be premixed or added individually.
The additive components and optional further additives can also be sprayed onto the polymer substrate.
The additive components and optional further additives can also be added to the polymer in the form of a master batch (“concentrate”) which contains the components in a concentration of, for example, about 2.0% to about 80.0% and preferably 5.0% to about 50.0% by weight incorporated in a polymer. The polymer is not necessarily of identical structure than the polymer where the additives are added finally. In such operations, the polymer can be used in the form of powder, granules, solutions, and suspensions or in the form of lattices.
Incorporation can take place prior to or during the shaping operation. The materials containing the additives of the invention described herein preferably are used for the production of molded articles, for example injection molded or roto-molded articles, injection molded articles, profiles and the like, and fibres, spun melt non-wovens, films or foams.
A further embodiment of the invention relates to a process for inducing the flame retardancy in polymers, which comprises adding to the polymer substrate at least one diphenylphosphino-N-derivative of the formula
Wherein
n represents zero or one;
X represents oxygen or sulphur;
R represents hydrogen, C1-C4alkyl, C6-C14aryl or C7-C15alkylaryl;
Or a group of the partial formula
Wherein
n represents zero or one;
X represents oxygen or sulphur;
the dotted line represents the bond to the other nitrogen atom;
A represents C2-C4alkylene, C5-C6-cycloalkylene, C1-C4alkyl-C5-C6-cycloalkylene, 1,2-, 1,3- or 1,4-phenylene, 2,4- or 2,6-tolylene or the group
and the dotted line represents the bond to the other nitrogen atom in formula IB.
Compounds (IB), wherein n is zero or one, X represents sulphur and A represents ethylene, are known according to O. Akba et al., J. Organometallic Chem. 2009, 694, 731.
Compounds (IB), wherein n is zero or one, X represents oxygen and A represents ethylene, are known according to B. Gümgüm et al., Polyhedron 2006, 25, 3133.
Compounds (IB), wherein n is zero and A represents ethylene, are known according to T. Jiang et al., Chin. Science Bull. 2006, 51(5), 521-523.
Compounds (IB), wherein n is zero and A represents 1,4-phenylene, are known according to K. G. Gaw et al., J. Organometallic Chem. 2002, 664, 294 and T. Jiang, loc. cit.
Compounds (IB), wherein n is zero and A represents 1,3-phenylene, such as N,N,N′,N′-tetrakis(diphenylphosphino)benzene-1,3-diamine:
are known according to N. Biricik et al. Helv. Chim. Acta 2003, 85, 3281 or from M. Alajarin et al., Science of Synthesis 2007, 31b, 1873-1884; F. Majoumo-Mbe et al., Dalton Transactions 2005, 20, 3326-3330; F. Majoumo-Mbe et al., Zeitschrift für Anorganische and Allgemeine Chemie 2004, 630(2), 305-308.
Compounds (IB), wherein n is one, X represents sulphur and A represents 1,3-phenylene, such as N,N′-(1,3-phenylene)-bis(N-(diphenylphosphorothioyl)-P,P-diphenylphosphinothioic amide):
are known according to N. Biricik et al. Helv. Chim. Acta 2003, 85, 3281.
The polymer substrate suitable for inducing flame retardancy has been described above.
A further embodiment of the invention relates to a process for inducing the flame retardancy in polymers, which comprises adding to the polymer substrate at least one bis[di(9,10-dihydro-9-oxa-10-phosphaphenanthrene)-N-benzol]sulphonyl-derivative of the formula
Wherein
n represents zero or one; and
X represents oxygen or sulphur.
Compounds (IC) are novel and are also subject matter of the invention. The polymer substrate suitable for inducing flame retardancy has been described above.
A further embodiment of the invention relates to a P—N-compound selected from the group consisting of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-N-derivatives of the formula
Wherein
X represents oxygen or sulphur;
R represents hydrogen or a hydrocarbon radical selected from the group consisting of C1-C4alkyl, C5-C6cycloalkyl, (C1-C4alkyl)1-2C5-C6cycloalkyl, C6-C14aryl and C7-C15alkylaryl;
or represents a group of the partial formula
Wherein
X represents oxygen or sulphur;
A represents C2-C4alkylene, C5-C6-cycloalkylene, (C1-C4alkyl)1-2C5-C6cycloalkylene, 1,2-, 1,3- or 1,4-phenylene, 2,4- or 2,6-tolylene or the group
and the dotted line represents the bond to the other nitrogen atom in formula la; and
Diphenylphosphino-N-derivatives of the formula
Wherein
R represents a group of the partial formula
Wherein the dotted line represents the bond to the other nitrogen atom in formula IB; and
A represents C3-C4alkylene, C5-C6-cycloalkylene, (C1-C4alkyl)1-2C5-C6cycloalkylene, 1,2-, 1,3- or 1,4-phenylene, 2,4- or 2,6-tolylene or the group
Diphenylphosphino-N-derivatives of the formula (Ia) defined above are obtainable by known methods, e.g. by subjecting a 9,10-dihydro-9-oxa-10-phosphaphenanthrene)-N-compound of the formula
Wherein
R represents hydrogen, C1-C4alkyl, C6-C14aryl or C7-C15alkylaryl,
Or a group of the partial formula
Wherein A represents C2-C4alkylene, C5-C6-cycloalkylene, (C1-C4alkyl)1-2C5-C6cycloalkylene, 1,2-, 1,3- or 1,4-phenylene, 2,4- or 2,6-tolylene or the group
and the dotted line represents the bond to the other nitrogen atom in formula Ib;
to an oxidation reaction, or in-situ when incorporating into an organic polymer, for example by aerobic oxidation, or by extrusion in the presence of air or another oxidation agent, such as a peroxide or hydrogen peroxide.
This oxidation step is also subject matter of the present invention.
9,10-Dihydro-9-oxa-10-phosphaphenanthrene)-N-compounds of the formula lb are obtainable by known methods, e. g. by amidation or transamidation reactions, such as the ones described in U.S. Pat. No. 4,380,515.
The starting material 9,10-dihdro-9-oxa-10-phosphaphenanthrene-10-chloride (DOP-Cl) is obtainable by methods known in the literature, such as the ones described in EP 0 582 957.
The starting materials diphenylphosphino-N-derivatives (IB′) defined above are obtainable by known methods, e.g. by subjecting a diphenylphosphine-N-derivative of the formula
Wherein
R represents a group of the partial formula
Wherein the dotted line represents the bond to the other nitrogen atom in formula IB; and
A represents C2-C4alkylene, C5-C6-cycloalkylene, (C1-C4alkyl)1-2C5-C6cycloalkylene, 1,2-, 1,3- or 1,4-phenylene, 2,4- or 2,6-tolylene or the group
to an oxidation reaction, or in-situ when incorporating into an organic polymer, for example by aerobic oxidation, or by extrusion in the presence of air or another oxidation agent, such as a peroxide or hydrogen peroxide.
This oxidation step is also subject matter of the present invention.
The starting material diphenylphosphine-N-derivative of the formula
Wherein
R represents a group of the partial formula
Wherein the dotted line represents the bond to the other nitrogen atom in formula IB; and
A represents C2-C4alkylene, C5-C6-cycloalkylene, (C1-C4alkyl)1-2C5-C6cycloalkylene, 1,2-, 1,3- or 1,4-phenylene, 2,4- or 2,6-tolylene or the group
is available by known methods.
The starting materials, wherein A represents ethylene, are known according to B. Gümgüm et al., Polyhedron 2006, 25, 3133 or from T. Jiang et al., Chin. Science Bull. 2006, 51(5), 521-523; O. Akba et al., J. Organometallic Chem. 2009, 694, 731.
The starting materials, wherein A represents 1,4-phenylene, are known according to K. G. Gaw et al., J. Organometallic Chem. 2002, 664, 294 and T. Jiang et al. loc. cit.
The starting materials, wherein A represents 1,3-phenylene, are known according to M. Alajarin et al., Science of Synthesis 2007, 31b, 1873-1884; F. Majoumo-Mbe et al., Dalton Transactions 2005, 20, 3326-3330; F. Majoumo-Mbe et al., Zeitschrift für Anorganische and Allgemeine Chemie 2004, 630(2), 305-308.
Compounds of the formula
Wherein
n represents zero or one; and
X represents oxygen or sulphur;
are obtainable by known methods, such as reaction of DOP-Cl with 4,4′-diaminodiphenylsulphone, and, where required, subsequent reaction with an oxidation agent, such as a peroxide or hydrogen peroxide, or by reaction with elemental sulphur.
The following Examples illustrate the invention
A 500 ml flame dried three neck flask equipped with a condenser, a stirring bar and an addition funnel is charged with aniline (13.9 g, 149 mmol) and N-methylimidazole (100.0 g, 1.22 mol) as a solvent and auxiliary base. The addition funnel is filled with melted DOP-Cl (70.0 g, 298 mmol) which is added slowly to the reaction mixture at 4° C. A heating gun is used to keep DOP-Cl liquid. The reaction mixture is kept at 40° C. for 14 h. After completion of the reaction, the crude product is poured into 200 ml of water. The white precipitate is removed by filtration and rinsed twice with water and acetone. The final product is dried at 13 mbar and 120° C. to yield 59.7 g (120 mmol, 80%) of a white solid (2 diastereomers) having a melting point range of 208-211° C.
31P NMR (101 MHz, CDCl3): δ 90.1 (s), 89.7 ppm (s).
1H NMR (400 MHz, CDCl3): δ 7.69-7.65 (m, 1H), 7.64-7.55 (m, 2H), 7.43-7.21 (m, 8H), 7.16 (td, J=7.2 Hz, J=1.2 Hz, 1H), 7.10-7.08 (m, 1H), 6.96-6.90 (m, 2H), 6.86 (t, J=7.6 Hz, 1H), 6.47 (t, J=7.5 Hz, 1H), 6.38 (t, J=7.4 Hz, 1H), 6.24 (t, J=7.5 Hz, 2H), 6.10 (t, J=7.5 Hz, 2H), 5.71, (d, J=7.8 Hz, 2H), 5.53 ppm (d, J=8.2 Hz, 2H).
IR (KBr): μm 3058 (vw), 1582 (vs), 1475 (s), 1202 (s), 919, 859 (vs), 755, 711, 669, 528, 340 cm−1.
HR-MS (EI) calcd. for [12C30H21NP2O2]: 489.1048, found: 489.1208 [M]+.
A flame dried three neck flask equipped with a condenser, stirrer and addition funnel is charged with the product obtained according to Example 1.1 (14.2 g, 29.0 mmol) and 100 ml dry toluene. A solution is obtained at 40° C., which is cooled to room temperature again. tert-Butyl hydroperoxide (5.40 g, 60.0 mmol) dissolved in 12.1 g toluene is added slowly under vigorous stirring. The reaction is slightly exothermic and cooled with a water bath. After completion, the solvent is removed in vacuo to yield 13.8 g (26.4 mmol, 91%) of a light yellow solid having a melting point of 155-156° C.
31P NMR (101 MHz, CDCl3): δ 7.89 ppm (s).
1H NMR (400 MHz, CDCl3): δ 8.15-8.09 (m, 1H), 7.93-7.87 (m, 1H), 7.81-7.75 (m, 2H), 7.71-7.68 (m, 2H), 7.63-7.56 (m, 2H), 7.48-7.39 (m, 2H), 7.23-7.19 (m, 1H), 7.11-7.01 (m, 3H), 6.95-6.84 (m, 4H), 6.77 (t, J=7.9 Hz, 1H), 6.73-6.72 ppm (m, 2H).
IR (KBr): μm 3065 (vw), 1595 (vs), 1560 (vs), 1477 (s), 1431, 1263 (vs), 1199, 1000 (vs), 905 (vs), 752 (vs), 697, 530 cm−1.
1.3 6,6′-(Phenylazanediyl)-bis(6H-dibenzo[c,e][1,2]oxaphosphinine-6-sulphide)
The product obtained according to Example 1.1 (33.7 g, 68.8 mmol) is dissolved in 100 ml toluene at 65° C. Sulphur (4.41 g, 138 mmol) is added in small portions at this temperature over a period of 30 min. The reaction mixture is stirred at room temperature for 2 hours and at 120° C. over night. After completion, the solvent is removed in vacuo. 33.9 g (61.2 mmol, 90%) of a white product are obtained having a melting point range of 175-180° C.
31P NMR (101 MHz, CDCl3): δ 64.1 ppm (s).
1H NMR (250 MHz, CDCl3): δ 7.94-7.78 (m, 1H), 7.64-6.84 (m, 18H), 6.75-6.72 ppm (m, 2H).
IR (KBr): μm 3061 (vw), 1473 (s), 1189 (s), 1115, 966 (vs), 929 (vs), 885, 751 (vs), 660, 521, cm−1.
HR-MS (EI) calcd. for [12C30H21P2O2S2N]: 553.0489, found: 553.0447 [M]+.
A 1000 ml flame dried three neck flask equipped with a condenser, a stirring bar and an addition funnel is charged with m-phenylene diamine (16.1 g, 149 mmol) and N-methylimidazole (200.0 g, 2.44 mol). The addition funnel is charged with melted DOP-Cl (140.0 g, 596 mmol) which is added slowly to the reaction mixture at 40° C. A heating gun is used to keep DOP-Cl liquid. The reaction is slightly exothermic. The reaction mixture is kept at 40° C. for 3 h and heated to 70° C. over night. After completion (monitored by NMR spectroscopy), the crude product is poured into 500 ml of water. The white precipitate is removed by filtration and rinsed three times with water and acetone (each time). The product is dried at 13 mbar and 140° C. to yield 41.0 g (45.0 mmol, 91%) of a white solid (mixture of diastereomers) having a melting point range of 270-275° C.
31P NMR (101 MHz, CDCl3): δ 88.8-88.1 (m), 87.7-85.8 ppm (m).
1H NMR (400 MHz, CDCl3): δ 7.79-6.84 (m, 32H), 6.04-5.87 ppm (m, 4H).
IR (KBr): μm 3056 (vw), 1581 (vs), 1473 (s), 1204, 1113 (s), 930 (vs), 763, 750, 618, 474 cm−1.
HR-MS (EI) calcd. for [12C54H36N2P4O4]: 900.1626, found: 900.2017 [M]+.
A flame dried three neck flask equipped with a condenser, stirrer and addition funnel is charged with the product obtainable according to Example 1.4 (50.0 g, 55.5 mmol I) and 120 ml dry toluene. The reaction mixture is heated to 30° C. and a solution of tert-butyl hydroperoxide (20.5 g, 228 mmol) in 48 ml toluene is added slowly under vigorous stirring. The reaction is slightly exothermic and is kept at 30-40° C. using a water bath. After completion, the solvent is removed in vacuo to yield 48.9 g (50.7 mmol, 91%) of a light yellow solid (mixture of diastereomers) having a melting point range of 176-180° C.
31P NMR (101 MHz, CDCl3): δ 8.12-7.44 ppm (m).
IR (KBr): μ 3062 (vw), 1595 (s), 1477 (vs), 1269 (vs), 1119, 1001 (s), 981 (s), 754, 517, 425 cm−1.
HR-MS (EI) calcd. for [12C54H36N2P4O8]: 964.1422, found: 964.1290 [M]+.
The product obtainable according to Example 1.4 (50.7 g, 56.3 mmol) is dissolved in 200 ml toluene at 60° C. Sulphur (7.21 g, 225 mmol) is added in small portions at this temperature over a period of 45 minutes. The reaction mixture is stirred at room temperature for 2 hours and at 120° C. for 2 days. After completion, the solvent is removed in vacuo. 51.1 g (49.6 mmol, 88%) of a yellow product (mixture of diastereomers) is obtained having a melting point range of 177-185° C.
31P NMR (101 MHz, CDCl3): δ 66.1-61.9 ppm (m).
IR (KBr): μm 3061 (vw), 1581 (m), 1474 (s), 1199, 1115 (s), 951 (vs), 915 (vs), 861, 790, 751, 717, 662 cm−1.
HR-MS (EI) calcd. for [12C54H36P4S4O4N2]: 1028.0508, found: 1028.0818 [M]+.
A 1000 ml flame dried three neck flask equipped with a condenser, a stirring bar and an addition funnel is charged with ethylenediamine (8.96 g, 149 mmol) and N-methylimidazole (200.0 g, 2.44 mol). The addition funnel is charged with melted DOP-Cl (140 g, 596 mmol) which is added slowly to the reaction mixture at 40° C. The reaction is slightly exothermic. The reaction mixture is kept at 40° C. for 6 h and heated to 80° C. over night. After completion, the crude product is poured into 500 ml of water. The precipitate is removed by filtration and rinsed three times with water and acetone each. The product is dried at 13 mbar and 140° C. to yield 120 g (140 mmol, 94%) of a white solid melting at 330-335° C. under decomposition.
IR (KBr): μm 3058 (vw), 2928 (vw), 1581 (m), 1474 (s), 1427, 1202, 1115 (s), 1051, 880 (vs), 853, 750, 620, 473 cm−1.
HR-MS (EI) calcd. for [12C50H36N2P4O4]: 852.1626, found: 852.1992 [M]+.
The product obtainable according to Example 1.7 (50.0 g, 58.6 mmol) is reacted with tert-butylhydroperoxide (21.2 g, 235 mmol) dissolved in toluene according to the procedure described in Example 1.2 to yield 49.5 g (53.9 mmol, 92%) of a white powder. The product is present as a mixture of diastereomers and melts at 325° C. under decomposition.
31P NMR (101 MHz, CDCl3): δ 12.1 (s, 2P), 11.8 ppm (s, 2P).
1H NMR (250 MHz, CDCl3): δ 7.84-7.54 (m, 16H), 7.40-6.82 (m, 16H), 4.19-3.91 ppm (m, 4H).
IR (KBr): μm 3064 (vw), 2957 (vw), 1596 (w), 1479 (vs), 1261 (vs), 1119 (s), 963 (vs), 754, 513, 417 cm−1.
The product obtainable according to Example 1.7 (19.4 g, 22.7 mmol) is reacted with sulphur (2.91 g, 91.0 mmol) according to the procedure described in Example 1.3. The reaction is complete after 2 days. 18.0 g (18.3 mmol, 95%) of a light yellow solid (mixture of diastereomers) are obtained having a melting point range of 243-250° C.
31P NMR (101 MHz, CDCl3): δ 70.2-68.7 ppm (m).
IR (KBr): μm 3061 (vw), 2984 (vw), 1580 (w), 1472 (s), 1194, 1115 (s), 922 (vs), 895 (vs), 748, 726, 625, 472 cm−1.
HR-MS (EI) calcd. for [12C54H36P4S4O4N2]: 1028.0508, found: 1028.0818 [M]+.
N,N,N′,N′-tetrakis(diphenylphosphino)benzene-1,3-diamine (96.0 g, 114 mmol) is reacted with tert-butylhydroperoxide (40.1 g, 445 mmol) dissolved in toluene according to the procedure described in Example 1.2. The product is precipitated by addition of ethyl acetate to yield 91.5 g (101 mmol, 98%) of a white solid having a melting point range of 265-269° C.
31P NMR (101 MHz, CDCl3): δ 27.6 ppm (s).
1H NMR (250 MHz, CDCl3): δ 8.51 (s, 1H), 7.96 (s, 8H), 7.57 (s, 8H), 7.37 (s, 12H), 7.14-7.02 (m, 12H), 6.41 (d, J=7.6 Hz, 2H), 6.08 ppm (t, J=7.9 Hz, 1H).
IR (KBr): μm 3057 (vw), 1589 (s), 1438 (vs), 1205 (vs), 1119, 952 (s), 731, 695, 518 cm−1.
HR-MS (EI) calcd. for [12C54H44O4P4N2]: 908.2559, found: 908.2559 [M]+.
A 500 ml flame dried four-necked flask equipped with a condenser, a stirring bar and an addition funnel is charged with 4,4′-sulphonyldianiline (12.4 g, 50.0 mmol) under an argon atmosphere. The addition funnel is charged with melted DOP-Cl (52.5 g, 224 mmol), which is kept liquid using a heating gun. 4,4′-sulphonyldianiline is dissolved in N-methylimidazole (82.0 g, 1.00 mol). After cooling to 40° C., DOP-Cl is added dropwise over a period of 40 min, so that the temperature of the reaction system is maintained at 50-55° C. The mixture is further stirred for 5 h at 60° C. After completion of the reaction (monitored by NMR spectroscopy), the crude product is poured into 350 ml of water. The precipitated white solid is filtered off and dissolved in 350 ml of toluene. The solution is ex-tracted three times with 100 ml of water and dried over sodium sulphate. The solvent is removed in vacuo to give a foam-like solid, which is crushed and dried at 12 mbar and 160° C. to yield 45.0 g (43.0 mmol, 86%) of a white solid (mixture of diastereomers).
31P NMR (101 MHz, CDCl3): δ 90.5-89.0 ppm (m).
MS (EI): 1041 (M+1).
A flame dried three neck flask equipped with a condenser, stirrer and addition funnel is charged with the product obtained according to 1.11 (10.4 g, 10.0 mmol) which is dissolved at 40° C. in 70 ml dry toluene under an argon atmosphere. The reaction mixture is cooled to 5° C. with an ice bath, and 13.6 g of a solution of H2O2 (11% in ethyl acetate, 44 mmol) is added slowly under vigorous stirring. The temperature of the reaction mixture is kept below 15° C. During the reaction a solid separates at the bottom of the reaction vessel containing the product formed. After completion of the reaction, the solid is isolated by decantation, rinsed with ethyl acetate and toluene and dried in vacuo at 160° C. for 2 h to yield 9.1 g (8.24 mmol, 82%) of a white powder (mixture of diastereomers).
31P NMR (101 MHz, CDCl3): δ 7.7-7.4 ppm (m).
MS (EI): 1105 (M+1).
The product obtained according to 1.11 (12.5 g, 12.0 mmol), sulphur (1.60 g, 50.0 mmol) and xylene are heated to reflux under an argon atmosphere for 6 h. During the reaction a viscous phase separates at the bottom of the reaction vessel containing the product formed. After completion of the reaction (monitored by NMR spectroscopy), the upper phase is removed. The viscous residue is heated to 200° C. in vacuo and the obtained solid is crushed to yield 12.7 g (10.9 mmol, 90%) of a white powder (mixture of diastereomers).
31P NMR (101 MHz, CDCl3): δ 63.9-63.0 ppm (m).
MS: 1171 (M+2).
A 500 ml flame dried four-necked flask equipped with a condenser, a stirring bar and an addition funnel is charged with DOP-Cl (31.3 g, 133 mmol) and 200 ml of dry toluene under an argon atmosphere. The obtained solution is cooled to 5° C. and triethylamine (16.5 g, 160 mmol) is added. A solution of toluidine (7.13 g, 66.5 mmol) in 50 ml toluene is added over a period of 40 min under vigorous stirring. The temperature of the reaction mixture is kept below 10° C. with an ice bath. The reaction mixture is stirred at 10° C. for 80 min and is kept at ambient temperature for 48 h. During the reaction a white solid precipitates which is removed by filtration. The suspension is heated to 60° C. before filtration. Afterwards the solid is rinsed two times with warm toluene (40° C.). The organic phases are combined and the solvent is distilled off in vacuo. The crude product is dissolved in 200 ml of boiling toluene to which 300 ml of acetonitrile are added. On cooling the product is obtained as white crystals. The crystals are dried in vacuum at 100° C. to yield 23.7 g (47.0 mmol, 71%) of the product having a melting point of 193-196° C.
31P NMR (101 MHz, CDCl3): δ 91.0 (s, 2P), 90.5 ppm (s, 2P).
1H NMR (250 MHz, CDCl3): δ 7.66-7.61 (m, 3H), 7.47-7.20 (m, 9H), 7.12-7.09 (m, 1H), 7.01-6.90 (m, 3H), 6.19 (d, J=8.1 Hz, 2H, HA), 5.99 (d, J=8.1 Hz, 2H, HA″), 5.67 (d, J=8,1 Hz, 2H, HB), 5.47 (d, J=8.1 Hz, 2H, HB′), 1.92 (s, 3H, HC), 1.85 ppm (s, 3H, HC′).
MS (EI): 504 (M+1).
The product obtained according to 1.14 (10.1 g, 20.0 mmol), sulphur (1.28 g, 40.0 mmol) and xylene (60 ml) are heated to reflux under an argon atmosphere for 6 h. After completion of the reaction (monitored by NMR spectroscopy), the reaction mixture is cooled down to ambient temperature. The precipitated solid is collected by filtration and rinsed with cold toluene and dried in vacuo at 100° C. The product is obtained as a light brown solid (mixture of diastereomers) at a yield of 10.1 g (17.8 mmol, 89%) having a melting point range of 265-268° C.
31P NMR (101 MHz, DMSO-d6): δ 64.9 (d, 2P), 64.8 ppm (d, 2P).
MS (EI): 568 (M+1).
A 1 l three neck flask equipped with a condenser, stirring bar and addition funnel is charged with N-methylimidazole (150.0 g, 1.80 mol) and 2,4-diaminotoluene [(TDA) 18.2 g, 149 mmol]. TDA is dissolved at 40° C. DOP-Cl (140.0 g, 597 mmol) is melted at 100° C. and transferred into the addition funnel. The DOP-Cl melt is added to the reaction solution under vigorous stirring at 40° C., while the melt is kept liquid with a heating gun. After completion of addition, the reaction mixture is heated to 100° C. and stirred over night. The reaction mixture is poured into 500 ml of water and the product is filtered off. The crude product is washed three times with water and two times with acetone. Solvent traces are removed at 12 mbar and 120° C. in vacuum to yield 138 g (150 mmol, 94%) of a white solid having a melting point range of 270-283° C.
31P-NMR (101 MHz, CDCl3): δ 88.4 ppm (s).
HR-MS (EI) calcd. for [12C55H38O4P4N2]: 914.2211, found: 914.1782 [M]+.
A 500 ml two neck flask equipped with a condenser, stirring bar and an addition funnel is charged with the product obtained according to 1.16 (11.2 g, 12.2 mmol) and 50 ml toluene. The suspension is cooled with an ice bath to 5° C. A H2O2 solution in ethyl acetate (10%, 17.0 g, 50 mmol) is added slowly under vigorous stirring. Upon completion of the reaction the product is filtered off and rinsed with toluene to yield 10.2 g (10.4 mmol, 82%) of a white powder (mixture of diastereomers) having a melting range of 270-284° C.
31P-NMR (101 MHz, DMSO-d6): δ 8.50 (s), 7.37 ppm (s).
The flammability of the test specimen is assessed according to UL 94 standards described in Flammability of Plastic Materials for Parts in Devices and Appliances, 5th edition, Oct. 29, 1996.
The thermal properties of laminates are determines by Differential Scanning calorimetry (DSC) according to IPC-TM-650 2.4.25 for the determination of glass transition temperatures (Tg).
Phenol Novolak epoxy resin: DEN 438, Dow;
Dicyandiamide (DICY): Dyhard® 100S, AlzChem, Germany Fenuron: DYHARD UR 300, AlzChem, Germany.
The desired amount of the flame retardant additive, 6 parts dicyandiamide and 2.0 parts Fenuron are combined with 100 parts of epoxy resin (DEN 438) at 90° C. and mixed in a high-speed dissolver DISPERMAT (VMA-Getzmann GmbH, Germany) at 6000 rpm under vacuum for 5 min. The formulation is transferred into an aluminium mold and cured at 110° C. for 1 hour, 130 C for 1 hour and post-cured at 200° C. for 2 hours. All samples are allowed to cool down slowly to room temperature to avoid cracking.
1)Parts per hundred resin
2)Not classified
cf. N. Biricik et al. Helv. Chim. Acta 2003, 85, 3281
The results presented above demonstrate that the inventive compounds and the inventive resin compositions exhibit flame retardant properties (UL94 V-1 and V-0 classification) at relatively low levels of additives loading. Resin compositions containing the inventive flame retardants exhibit high Tg-values which are close to or even exceeding the value obtained for the reference composition without flame retardant additive. It is desirable for many applications, especially for laminates being used for the manufacture of printed circuit boards, that the flame retardant additive has none or little negative influence on the Tg of the resin composition. Industrial practice has shown that variations <15° C. are acceptable for many applications.
o-Cresol Novolak epoxy resin: Araldite® ECN 1280, Huntsman Advanced Materials, Ba-sel, Switzerland;
Hardeners: dicyanodiamide (DICY), Aldrich, Germany; Phenol Novolac (PN): Durite® SD 1702, Hexion, Switzerland;
Accelerator: 2-methylimidazole, Aldrich, Germany;
Solvents: 1-methoxy-2-propanol and dimethylformamide (DMF), both Merck Eurolab, Germany;
Glass cloth: Type 7628, P-D Interglas Technologies AG, Germany.
A resin formulation is prepared by dissolving various quantities of ARALDITE ECN 1280 resin in 37.5 parts per hundred resin (phr) of methoxy-2-propanol at 95° C. 0.04 phr of 2-methylimidazole, the flame-retardant additives, as specified in Table 2, and 8.13 phr of DICY as a solution in a 1:1 mixture of 1-methoxy-2-propanol and DMF are added.
The formulation is hot coated onto a piece of glass cloth (type 7628) and heated to 170 C for about 1.5-2 min in a forced draft oven. The fibre, now a non-tacky prepreg, is cut into seven strips (˜180×180 mm) which are stacked upon each other in a distance holder to assure the manufacture of laminates with uniform thicknesses of 1.6 mm. The strips are covered with two PTFE plates of 1 mm thickness on the upper and the lower side of the prepreg stack. The stack is placed on a hot press, and the stacked prepregs are subjected to a pressure of 3 bar at 170° C. for a period of 2 h.
The resulting laminate is removed from the hot press, cooled to ambient temperature under 3 bar pressure, and separated from the distance holder and PTFE plates. The laminate is cut to a piece of ˜150×150 mm by cutting off the edges with varying amounts of resin, weighed, its thickness measured, and its percent resin content determined. Test bars of the required dimensions are obtained by water jet cutting of the laminates.
Stock formulations of Araldite® ECN 1280 (85 wt.-%) and PN (50 wt.-%) in 1-methoxy-2-propanol are prepared. To obtain the desired resin formulations, the appropriate quantity of the stock solution of ECN 1280 is mixed with 44.4 phr of the PN stock solution at 60° C. for 30 min. Additional 1-methoxy-2-propanol is added if necessary to adjust the viscosity of the formulation. 0.10 phr 2-Methylimidazole and the flame-retardant additives as specified in Table 3 are added and homogenized with the resin solution.
The formulation is hot coated onto a piece of glass cloth (type 7628) and heated to 170° C. for about 1.5-2 min in a forced draft oven. The fibre, now a non-tacky prepreg, is cut into seven strips (˜180×180 mm) which are stacked upon each other in a distance holder to assure the manufacture of laminates with uniform thicknesses of 1.6 mm. The strips are covered with two PTFE plates of 1 mm thickness on the upper and the lower side of the prepreg stack. The stack is placed on a hot press, and the stacked prepregs are subjected to a pressure of 3 bar at 190 C for a period of 4 h.
The resulting laminate is removed from the hot press, cooled to ambient temperature under 3 bar pressure, and separated from the distance holder and PTFE plates. The laminate is cut to a piece of ˜150×150 mm by cutting off the edges with varying amounts of resin, weighed, its thickness measured, and its percent resin content determined. Test bars of the required dimensions are obtained by water jet cutting of the laminates.
c.f. N. Biricik et al. Helv. Chim. Acta 2003, 85, 3281
The results presented above demonstrate that the inventive compounds and the inventive resin compositions exhibit excellent flame retardant properties (UL94 V-1 and V-0 classification). Resin compositions containing the inventive flame retardants, either alone or in combination with other flame retardants, give laminates with good laminate properties and excellent flame retardancy at relatively low levels of additives loading.
Polybutyleneterephthalate (PBT): ULTRADUR® B 4500 (BASF)
Polytetrafluoroethylene (PTFE): DYNEON® PA 5931 (3M Corp.)
Glass fibers (GF): HP3786, 4.5 mm (PPG)
Diethylphosphinic acid aluminum salt (DEPAL): EXOLIT® OP 1240 (Clariant)
Melamine polyphosphate (MPP): MELAPUR® 200 (BASF)
Aluminum hypophosphite (IP-A): PHOSLITE® IP-A (Italmatch)
Poly(2,6-dimethyl-1,4-phenylene oxide): PPO (ex Aldrich, Germany
Phenol Novolac (PN): DURITE® SD 1702 (Momentive)
Melam: obtainable according to EP 0794976
A twin-screw extruder (Prism Eurolab 16, Thermofisher Scientific, LID=25:1, barrel diameter 16 mm) is equipped with a gravimetric feeder, a 4 mm×10 mm extrusion die and a vacuum connector. The extruder is operated at 260-270° C. and 50-150 rpm. Temperatures and extrusion speed are adjusted to the individual sample viscosity. Before the extrusion process, ground PBT and all additives are dried in a vacuum oven at 13 mbar and 100° C. to remove traces of water. Ground PBT is mixed with the additives and transferred into the feeder under nitrogen atmosphere. The melt is extruded through the die, and the resulting strand is passed through two vertically arranged steel barrels and cooled on a conveyor belt. Test specimen according to the UL94 standard are obtained by cutting of the strand.
A micro-compounder (DSM Xplore®) equipped with two conical co-rotating screws and a free volume of 15 mL is used for the compounding of the mixtures specified in Table 5. Before compounding, all components are mixed and dried in a vacuum oven at 100° C. to remove traces of water. The mixtures are then fed from the top into the vertically positioned micro-compounder under nitrogen atmosphere. The mixtures are melted and homogenized at 260° C. and 80 rpm in batch mode (closed valve). After 3 min, the valve is opened and the melt transferred to a connected transfer container which is pre-heated at 260° C. This container is then placed into a DSM Xplore® micro injection moulding machine, and two test specimen according to the UL94 standard having a thickness of 1.6 mm are produced via injection molding at a mold temperature of 90° C. and a pressure of 16 bar.
The results presented above demonstrate that the inventive compounds and the inventive polymeric compositions exhibit flame retardant properties (UL94 V-2, V-1 and V-0 classification).
| Number | Date | Country | Kind |
|---|---|---|---|
| 11188740.2 | Nov 2011 | EP | regional |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP2012/072083 | 11/8/2012 | WO | 00 | 5/9/2014 |
| Number | Date | Country | |
|---|---|---|---|
| 61558452 | Nov 2011 | US |
