COMPOSITIONS OF ALKYLENE-ALKYL ACRYLATE COPOLYMERS HAVING IMPROVED FLAME RETARDANT PROPERTIES

Abstract: The disclosure of this application is directed to com­ positions comprising an alkylene-alkyl acrylate copolymer, a halogenated flame-retardant additive, an oxide, hydro­ xide, carbonate or sulfate of calcium or magnesium and antimony oxide as a second flame retardant additive. The compositions, as described, can be extruded about electri­ cal conductors to provide insulation thereon and also ex­ truded as jacketing about telephone wires and clables.

Description: This application is a continuation-in-part of my copending application serial number 944,336 filed September 21, 1978 and also a continuation-in-part of my copending applica tion serial number 127 509 filed March 551980. SUMMARY OF THE INVENTION This invention relates to compositions, having iVprQv- ed flame retardant properties and reduced gas evolution, on burning, which contain a copolymer of an alkylene-alkyl acry late a halogenated flame retardant additive, an antimony oxide and an oxide, carbonate, hydroxide or sulfate of magnesium or cal cium, and are particularly useful as jacketing material about industrial control cables and telephone wires and cables and as insulation about electrical conductors. BACKGROUND OF THE INVENTION Compositions based on olefin polymers, such as Co- polymers of an alkylene-alkyl acrylate, by reason of their advantageous physical and electrical properties, have been suggested for use in various commercial applications. For example, alkylene-alkyl-acrylate copolymers are corrosion resistant, tough and abrasion resistant. Consequently, alkylene-l alkyl acrylate copolymers have been suggested for use in compositions to be used as jacketing material about industrial control cables and telephone wires and cables and as insulation about electrical conductors. Although alkylene-alkyl acrylate copolymers have properties which make them desirable for use in compositions which are to be used as jacketing material and as insulation, as described, alkylene-alkyl acrylate copolymers suffer the disadvantages of being flammable. In order to render these copolymers flame retardant and also, in order to reduce gas evolutton, on burning, a halogenated flame retardant additive and an alkaline earth metal salt or base have been added thereto, as described in my copending applications which have been previously identified. Compositions, disclosed in my copending applications, the disclosures of which applications are incorporated herein by reference, are conimercially attractive systems which are flame retardant, and upon burning, do not produce dense smoke, do not evolve high levels of acidic and corrosive gases and, in addition, exhibit reduced after-glow. Currently, in light of more stringent industry standards and more stringent government regulations, there is an immediate need for compositions which are characterized by a higher degree of flame retardancy with no unacceptable degradation of other desirable properties previously discussed. DESCRIPTION OF THE INVENTION The present invention provides compositions which meet the need of improved flame retardancy while maintaining accept able standards with respect to other desirable properties. Compositions of the present invention, useful for the applications- described, comprise a normally solid alkylenealkyl acrylate copolymer, from about one to about 30 percent by weight and preferably from about 5 to about 20 percent by weight of a halogenated flame retardant additive, from about 0.5 to about 30 percent by weight, preferably from about 2.5 to about 12 percent by weight of an oxide, carbonate, hydroxide or sulfate of magnesium or calcium and from about 0.5 to about 15 percent by weight, preferably from about one to about 10 percent by weight of an antimony oxide. In those instances wherein the compositions are to be used in molding applications to form such articles as flame retardant waste paper baskets, household fixtures and the like, the amount of alkaline earth metal salt or base in the compositions can be about 0.5 to about 50 percent by weight. A particularly desirable composition for use as insulation about electrical conductors comprises a normally solid alkylene-alkyl acrylate copolymer from about one to about 30 percent by weight of a halogenated flame retardant additive, from about 0.5 to 20 percent by weight of an alkaline earth metal salt or base, as described, and from about one to about 5 percent by weight of an antimony oxide. -A particularly desirable composition for use as Jacketing about industrial control cables and telephone wires and cables comprises a normally solid alkylene-alkyl acrylate copolyme from about one to about 30 percent by weight of a halogenated flame retardant additive, more than 20 and up to about 30 percent by weight of an alkaline earth metal salt or base, as described, and from about one to about 10 percent by weight of an antimony oxide. Percent by weight, unless otherwise specified, is based on the total weight of the composition, 100 percent by weight. Also, mixtures of materials can be used, if so desired. The alkylene-alkyl acrylate copolymers of the present invention are known products produced by reacting an alkene with an alkyl acrylate and usually contain about 2 to about 50 percent by weight combined alkyl acrylate. Suitable alkenes are ethylene, propylene, butene-l, isobutylene, pentene- 1, 2-methylbutene- 1, 3-methylbutene- 1, hexene, heptene-l, octene-l and the like. The alkylene moiety of the alkylene-alkyl acrylate copolymers contain from 2 to 18 carbon atoms inclusive, preferably 2 to 3 carbon atoms inclusive. Suitable alkyl acrylate monomers which are copolymerized with the alkenes fall within the scope of the following formula: EMI5.1 wherein R1 is hydrogen or methyl and R2 is alkyl having one to 8 carbon atoms inclusive. Illustrative compounds encompassed by this formula are; niethyl acrylate, ethyl acrylate, methyl methacrylate, n-butyl acrylate, t-butyl acrylate, n-butyl nethacrylate, 2-ethylhexyl acrylate and the like. Alkylene-alkyl acrylate copolymers generally have a density (ASTMD 1505) with a conditioning as in ASThD 147-72 of about 0.92 to about 0.94 and a melt index (ASTMD-l237 of 44 psi tested pressure) of about 0.5 to about 500 decigrams per minute. For purposes of the present invention, the preferred copolymer is ethylene-ethyl acrylate, generally having about three to about 40 percent by weight combined ethyl acrylate, preferably having abort 5 to about 20 percent by weight comb in ed ethyl acrylate. Combined alkyl acrylate is conveniently determined by infrared analysis. Halogenated flame retardant additives, useful for purposes of the present invention, are well known to those skilled in the art. These flame retardant additives ars halogenated (brominated or chlorinated) organic compounds. The preferred halogenated or ganic compounds include chlorinated polyethylene,polyvinyl chi ride, polyvinylidene chloride, polyvinyl chloride copolymers halogenated paraffin waxes, chlorinated altcyclic hydrocarbons, and brominated aromatic compounds. The most preferred include decabromodiphenyl oxide and compounds of the following formula: EMI6.1 wherein R is independently chlorine or bromine and n i)s an integer from 1 to 6 such as ethylene(bis-tetrabromophthalimide). The calcium or magnesium oxides, carbonates, hydroxides, or sulfates of the present invention are commercially available in different forms and grades. The calcium or magnesium oxides, carbonates, hydroxides, or sulfates may be optionally coated with any compatible hydrophobic material. The preferred coating materials are metal salts of fatty acids, organo silanes and organo titanates. Exemplary of the metal component of the salts of the fatty acids fall in Grnllp Ia, Ila or IIb of the Periodic Table (Handbook of Chemistry and Physics - 50th Edition). Acids used to form the metal salts are saturated or unsaturated monobasic or dibasic, branched or straight chain fatty acids of 8-20 carbon atoms4 Such atoms that may be included within the practice of this invention, but are not limited thereto, are palmitic, stearic, lauric, oleic, sebacic, ricinoleic, palmitoleic and the like. The preferred acid is stearic acid while the preferred metal salts are calcium stearate and zinc stearate. The organo silanes are preferably alkoxy silanes such as alkyl alkoxy silane, alkenyl alkoxy silane, alkynyl alkoxy silane, alkyl aryl alkoxy silane, alkenyl aryl alkoxy silane and alkynyl aryl alkoxy silane. Suitable alkoxy silanes include, for example, methyltriethoxy silane, methyl-tris (2-methoxyethoxy) silane, dimethyldiethoxy silane, allyltrimeth oxy silane and the like. Also suitable are the vinyl silanes such as vinyl-tris-(2-methoxyethoxy) silane, vinyl trimethoxy silane, vinyl triethoxy silane and the like. If desired, the organo silane, per se, can be included in the composition as an additive. Illustrative of suitable organo titanates fall within the scope of the following formula: Ti(oR3)4 - wherein R3 is a hvdrocarbon radical. Exemplary of organo titanates are tetrabutyl titanate, tetraisopropyl titanate and the like. The alkaline earth metal compounds can be coated by admixing about 0.05 to about 5 parts by weight of hydrophobic material per 100 parts by weight of alkaline earth metal salt or base in a two-roll mill, Henschel mixer, Waring blender and the like. Any of the antimony oxides, antimony trioxide, antimony tetra-oxide and antimony penta-oxide are suitable for purposes of the present invention. Antimony trioxide is preferred. Also, an antimony oxide in the nature of a complexed salt such as sold commercially by National Lead Co. under the trade name ONCOR can be used, if desired. These com flexed salts are exemplified by antimony oxide-zinc silicate salts. The compositions of the present invention can contain other additives, as is well known in the art, depending upon the ultimate use of the composition. For example, the compositions can contain peroxides to cure the compositions to crosslinked products, generally on the order of about O.Q5 to 4.0 percent by weight; antioxidants; conductive carbon blacks as well as other additives commonly used in moldable compositions, curable compositions compositions to be extruded into film material, compositions to be used as coatings, adhesive-s-and-the-like. When the *ompositions of the present invention are to be used in wire and cable or molding applications, it is advantageous that the compositions contain a filler. A preferred filler is talc, especially talc coated with a metal salt of a fatty acid, previously described. The compositions of the present invention are conveniently prepared by blending or compounding the components thereof in a suitable apparatus. The alkylene-alkyl acrylate copoly mer and the other desired components may be blended together by any of the techniques used in the art to blend and compound thermoplastics to homogeneous masses. Prior to or during the blending of the components together, the calcium or magnesium oxide, carbonate, hydroxide or sulfate may be coated by known techniques. As regards blending,the components may be fluxed on a variety of apparatus including multi-roll mills, screw mills, continuous mixers, extruders and Banbury mixers. When all the solid components of the compositions are available in the form of a powder, or as small particles, the compositions are most conveniently prepared by first making a blend of the components, for instance, in a Banbury mixer or a continuous extruder, and then masticating this blend on a heated mill, for instance a two-roll mill, and the milling continued until an intimate mixture of the components is obtained. In those Instances wherein the copolymer is not available in powder form, the compositions may be prepared by introducing the copolymer to a two-roll mill, masticating it until it forms a band around roll, after which a blend of the remaining components is added and the milling continued until an intimate mixture is obtained. The rolls are preferably maintained at a temperature which is within the range of 80 C to 135 C and-which is below the decomposition temperatures of the peroxide compound(s) if such are used. The composition, in the form of a sheet, is removed from the mill and then brought into a form, typically dice-like pieces, suitable for subsequent processing. The compositions may then be extruded onto a wire Dr cable, or other substrate. If the compositions of the present invention, are chemically curable, they are extruded Dnto the wire or cable, or other substrate and vulcanized at elevated temperatures of about) 180 < C and preferably at > 200 2304C using conventionaL vulcanizing procedures. The following examples are illustrative of the present Invention and are not intended to limit the scope thereof in my manner, Compositions were prepared by admixing components, Ldentified in Table 1, in a 40 gram Brabender mixer which had been preheated to a temperature of 120 C, for about five ninutes. After the five minute period, the contents of the Brabender were discharged, hot, flattened in a press and allowed to cool. Samples of each composition were used to prepare test plaques, having dimensions of 3 inches by 8 inches by 0.125 inch, in a press under the following conditions: Pressure 5000 psi Temperature - 180QC Time cycle - 15 minutes. Plaques were then subjected to the Limiting Oxygen test ASTND-2863-70, which is an indication of flame retardant properties. Formulations of Example 1 and Controls 1-3 were in parts by weight. The data of Table 1 clearly indicates, on a direct comparison, between a composition based on an alkylene-alkyl acrylate copolymer, i.e. ethylene-ethyl acrylate (Example 1) an a composition based on an ethylene-vinyl acetate copolymer (Con trol I) that the composition of Example 1 has superior flame retardant properties, 26.2 as compared to 23.3 for the composition of Control 1. The data of Example 1 and Controls 1-3 is further illuminating as it establishes that: when antimony oxide and an alkaline earth metal base or salt are both present in a composition based on an alkylene-alkyl acrylate copolymer the flame retardant properties of the composition are superior compared to a similar composition which does not contain an alkaline earth metal base or salt (Control 3 > 26.3 compared to 25.3. The signficance of the presence of an alkaline earth metal salt or base in a composition based on an alkylene-alkyl acrylate copolymer has been established in applicant's copending applications, previously identified, namely to prevent, upon burning, evolution of dense smoke, to reduce evolution of acidtc and corrosive gases and to reduce after glow. When antimony oxide and alkaline earth metal salt or base are both present in a composition based on ethylenevinyl acetate (Control 1) the flame retardant properties of the composition are poorer compared to a similar composition which does not contain an alkaline earth metal base or salt (Control 2); 23.3 compared to 24.2. TABLE 1 PERCENT BY WRIGGHT Formulation: Example 1 Control 1 Cotntrol 2 Control 3 Copolymer of ethylene-ethyl acrylate containig 15 percent by weight combined ethyl acrylate - melt index 1.6 55 -- -- 55 Copolymer of ethylene-vinyl acetate containing 10 pereent by weight combined vinyl acetate - melt index 2.0 -- 55 55 - Talc coated with zinc stearate 21.5 21.5 24 24 Antimony trioxide 2.5 2.5 2.5 2.5 Calcium carbonate 2.5 2.5 -- - Ethylene (Bis-tetrabromophthalimide) (flame retardant additive) 16.0 16.0 16.0 16.0 1,2-Dihydro-2,3,4-trimethyl quinoline (antioxidant) 0.5 0.5 0.5 0.5 Vinyl-tris(2-methoxyethoxy) silane 0.2 0.2 0.2 0.2 Di-&alpha; ;-cumyl peroxide 1.8 1.8 1.8 1.8 - - - - - - - - - - - - - - - - - - - - - - - - Limiting Oxygen Index 26.2 23.3 24.2 25.3 A masterbatch composition was prepared and samples thereof, with and without additional additives were tested for flame retardancy and evolution of smoke. The masterbatch composition had the following formulation: PERCENT BY WEIGHT Copolymer of ethylene-ethyl acrylate containing 15 percent by weight combined ethyl acrylate and having a melt index of L.6 58.9 Talc coated with zinc stearate 23.1 Ethylene(Bis-tetrabromophthalimide) 17.2 1,2-Dihydro-2,3,4-trimethyl quinoline 0.6 Vinyl-tris(2-methoxyethoxy) silane 0.2 To this masterbatch there was also added 1.5 percent by weight di-a-cumyl peroxide. Samples of the masterbatch composition, containing the peroxide and subsequently identified in Table II as MB were admixed with various additives and the resultant compositions were formed into plaques, all as previously described and tested for flame retardancy and evolution of smoke, upon burning. TABLE II PERCENT BY WEIGHT Example 2 Control 4 Control 5 Control 6 M.B. 88 100 98.5 90 Antimony trioxide 2 0 1.5 0 Calcium carbonate 10 0 0 10 - - - - - - - - - - - - - - - - - - - - - - Limiting Oxygen Index 26.5 23.8 24.6 25.3 Percent by weight smoke evolved, on burning, based on weight of sample burned 7.97 6.76 10.53 4.69 Similar results are achieved using one or more of the following: magnesium carbonate, magnesium oxide, magnesium hydroxide, magnesium sulfate, calcium oxide, calcium hydroxide and calcium sulfate in conjunction with an antimony oxide in alkylene-alkyl acrylate copolymer compositions as described herein.

Claims: WHAT IS CLAIMED IS: 1. A composition comprising an alkylene-alkyl acrylate copolymer, from about one to about 30 percent by weight of a halogenated flame retardant additive, from about 0.5 to about 50 percent by weight of an oxide, carbonate, hydroxide or sulfate of magnesium or calcium and from about 0.5 to about 15 percent by weight of an antimony oxide, preferably antimony trioxide. 2. A composition comprising an alkylene-alkyl acrylate copolymer, from about one to about 30 percent by weight of a halogenated flame retardant additive, from about 0.5 to about 30 percent by weight of an oxide, carbonate, hydroxide or sulfate of magnesium or calcium and from about 0.5 to about 15 percent by weight of an antimony oxide. 1 or 2 3. A composition as defined in claims | wherein the said copolymer is an ethylene-ethyl acrylate copolymer. 1 to 9 4. A composition as defined in claims / wherein the magnesium or calcium compound is present in an amount of from about 0.5 to 20 percent by weight. I to 3 5. A composition as defined in claims /wherein the magnesium or calcium compound is present in an amount more than 20 up to about 30 percent by weight. 1 to 3 6. A composition as defined in claims/ wherein the antimony oxide is present in an amount of about one to about -10 percent by weight. 1-to 3 7. A composition as defined in claims /comprising an alkylene alkyl acrylate copolymer, from about one to about 30 percent by weight of a halogenated flame retardant additive, from about 0.5 to 20 percent by weight of an oxide, carbonate, hydroxide or sulfate of magnesium or calcium and from about one to about 5 percent by weight of an antimony oxide. 1 to 3 8. A composition as defined in claims /comprising an alkylenealkyl acrylate copolymer, from about one to about 30 percent by weight of a halogenated flame retardant additive, more than 20 and up to about 30 percent by weight of an oxide, carbonate, hydroxide or sulfate of magnesium or calcium and from about one to about 10 percent by weight of an antimony oxide. 1 to 3 9. A composition as defined in claims / comprising an alkylene- alkyl acrylate copolymer, from about 5 to about 20 percent by weight of a halogenated flame retardant additive, from about 2.5 to about 12 percent by weight of an oxide, carbonate, hydroxide or sulfate of magnesium or calcium and from about one to about 10 percent by weight of an antimony oxide. 10. A composition as defined in claims 1 - 9 wherein the said oxide, carbonate, hydroxide or sulfate or magnesium or calcium is calcium carbonate, calcium oxide, calcium hydroxide, calcium sulfate, magnesium carbonate, magnesium oxide, magnesium hydroxide or magnesium sulfate. 11. A composition as defined in claims 1 - 10 wherein the oxide, carbonate, hydroxide or sulfate of magnesium or calcium is coated with an organo titanate, organo silane or a metal salt of a fatty acid. 12. A composition as defined in claim 1 - 11 which contains which a talc filler, preferably a talc filler/is coated with an organo silane, an organo titanate or a metal salt of a fatty acid. 13. A composition as defined in claiiml to 12 containing an organo silane. 14. A composition as defined in clainnl to 13 containing a peroxide. 15. The corsslinked product of the composition defined in claim 14. 16. The use of the compositions according to claims 1 to 14 for or the crosslinked composition of claim 15/insulating electrical conductors or jacketing wires or cables.

Inventors: KEOGH, MICHAEL JOHN
Applicants: UNION CARBIDE CORPORATION
Application year: 1981
Main classification: C08L23
IPC codes: C08K3, C08L33, C08L23