SILICONE FLAME RETARDANTS FOR NYLON

Abstract: There is provided a flame retardant composition compris­ ing: (a) about 50 to about 90 percent by weight of one or more nylon materials, and (b) about 10 to about 50 percent by weight of a composition effective for imparting flame resistance comprising: (i) about 20 to about 75 percent by weight based on (b) of diphenylsilanediol, low molecular weight phenyl substi­ tuted siloxane diol, or mixture thereof; (ii) about 3 to about 30 percent by weight based on (b) of Group IIA metal carboxylic acid salt; (iii) about 10 to about 60 percent by weight based on (b) of aluminum trihydrate; and (iv) about 10 to about 50 percent by weight based on (b) of organic halide.

Description: Background of the Invention The present invention relates to flame retardant compositions. More particularly, the present invention relates to flame retardant nylon plastic compositions and additive compositions which render nylon plastics substantially flame resistant. Nylon is the generic name for a family of polyamide polymers characterized by the presence of the amide group. The more common types of polyamide or nylon plastics are nylon-6, nylon-6,6, nylon-6, 10, nylon-11 and nylon-12. The nomenclature commonly employed in naming nylons is simply to designate the number of carbons in the repeating units; for example, the polyamide made from caprolactam; which contains six carbons, is known as nylon-6. If aminoundecanoic acid were instead employed, such monomer containing 11 carbon atoms, the resulting polyamide would be designated nylon-11. The reaction between hexamethylenediamine and adipic acid produces nylon-6, 6 and, similarly the reaction between sebacic acid and hexamethylenediamine produces nylon -6, 10. The manufacturing process of a particular polyamide is dependent upon the type of polymer being made. Polymerization of lactams, for example, requires opening of the ring structure, followed by linear chain growth. Polymers formed by reaction of amines and acids are produced by polycondensation, with formation of water. Polyamides that can be processed as solutions can be produced in the form of copolyamides based on combinations of nylon -6, 6, nylon-6 and nylon-6, 10. These materials have good oil resistance, abrasion resistance and adhesive qualities. Furthermore, special grades of nylon have been developed for processing as powders. In this case the most success has been achieved with nylon-11, since it possesses a relatively low melting point of 185°C, has low moisture absorption and good chemical resistance. One shortcoming of all of the foregoing nylon compositions is that they are not very flame resistant under the UL-94V rating system which, briefly, is as follows: "UL-94 V-0": Average flaming and/or glowing after removal of the igniting flame shall not exceed five seconds and none of the specimens shall drip particles which ignite absorbent cotton. "UL-94 V-I: Average flaming and/or glowing after removal of the igniting flame shall not exceed 25 seconds and none of the specimens shall drip particles which ignite absorbent cotton. "UL-94 V-II": Average flaming and/or glowing after removal of the igniting flame shall not exceed 25 seconds and the specimens drip flaming particles which ignite absorbent cotton. Japanese Kokai, JP 82/76,039, discloses fire resistant polyolefin compounds which contain 1 - 50% (based on the polyolefin) of the reaction product of a silane or siloxane having two or more halogen or hydroxyl groups with a boron-containing compound, with or without additional silicone oil. Thus, for example, diphenylsilanediol, boric acid and polydimethylsiloxane oil can be reacted to provide a borosiloxane effective for rendering a low density polyethylene substantially flame resistant. U.S. -A- 4,247,246 discloses a flame resistant composition comprised of a crosslinked olefin, decabromodiphenyl ether, silicone gum and dibasic lead phthalate. In U.S. -A- 4,273,691, there is disclosed a flame resistant composition comprised of a blend of organic polymer, silicone polymer, and a Group IIA metal carboxylate salt containing six to twenty carbon atoms. Copending European application 83900861.2 discloses flame retardant compositions similar to US'-A-4 273 691 but utilize silicone polymers having substantially lower viscosities. In U.S. -A 4,387,176 there is disclosed, that improved flame retardant or flame resistant thermoplastics are provided by adding thereto a silicone, a silicone resin which is soluble in said silicone and a Group IIA metal organic salt containing 6 or more carbon atoms. Included among the organic polymers which can be used to make the flame resistant compositions of Frye are polyamides such as nylon -6, 6 and nylon -12 etc. Although US-A-4,387,176 does provide excellent results in that nylon plastic improves from totally consumed by flames in only 175 seconds to a UL-94 rating of V-II, it is nevertheless desirable to provide nylon compositions which have a UL-94 rating of V-O or V-I. Each of the foregoing disclosures are incorporated by reference into the instant disclosure. It should be noted that the terms "flame resistant" and "flame retardant" are used interchangeably throughout and are intended to have the same meaning, i.e. having a UL-94 rating of V-O or V-I. Summary of the Invention It is one object of the present invention to provide nylon compositions which exhibit improved flame resistance or retardance. It is another object of the present invention to provide novel flame retardant additives for use in rendering nylon compositions substantially flame resistant. Still another object of the present invention is to provide processes for making the foregoing flame retardant additives and flame retardant nylon compositions. In accordance with the foregoing objects there is provided by the present invention an additive package or masterblend formulation effective for rendering nylon plastics substantially flame resistant when combined therewith, comprising: (i) 20 to 75 percent by weight of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol, 1,1,3,3,5,5-hexaphenyltrisiloxanediol or mixtures thereof, (ii) 3 to 30 percent by weight of a Group IIA metal C (6-20) carboxylic acid salt, (iii) 10 to 60 percent by weight aluminum trihydrate, and (iv) 10 to 50 percent by weight of organic halide, particularly decabromodiphenyloxide. In accordance with another aspect of the present invention there is provided a substantially flame resistant nylon plastic composition comprising: (i) 10 to 50 percent by weight of a flame retardant additive as hereinabove described, said flame retardant additive being substantially uniformly dispersed throughout; (ii) 50 to 90 percent by weight of one or more nylon plastic compositions. Description of the Invention The present invention is based on the surprising discovery that 10 to 50 parts by weight of a composition comprising (i) 20 to 75 percent by weight of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol, 1,1,3,3,5,5-hexaphenyltrisiloxanediol or mixtures thereof, (ii) 3 to 30 percent by weight of a Group IIA metal C (6-20) carboxylic acid salt, (iii) 10 to 60 percent by weight aluminum trihydrate, and (iv) 10 to 50 percent by weight of organic halide, particularly decabromodiphenyloxide can be mixed or blended with 50 to 90 percent by weight of a nylon plastic composition and thereby render said nylon composition substantially flame resistant. The first major ingredient of the flame retardant additive of the present invention is preferably a compound selected from the group consisting of diphenylsilanediol, e.g. 1,1,3,3 - tetraphenyldisiloxanediol, e.g. 1,1,3,3,5,5 - hexaphenyltrisiloxanediol, e.g. or mixtures thereof, where is phenyl. One of the primary purposes of such diol compounds is to eliminate flaming drops of nylon plastic which occur when the silane or siloxane diol is not included in the composition. Broadly, there can be from about 20 to about 75 parts by weight of diol compound per 100 parts by weight of flame retardant additive composition. If less than 20 parts by weight of diol composition is utilized per 100 parts flame retardant additive the resulting nylon plastic composition will not have a UL-94 rating of V-O or V-I. If more than about 75 parts by weight of diol compound is employed there will be insufficient amounts of the other ingredients present to provide the nylon effective flame resistance. The preferred diol for practicing the present invention is diphenylsilanediol as it is not only least expensive, but also, is the most effective. In a preferred embodiment of the present invention there is present from about 25 to about 45 parts by weight of diol compound, and most preferably from about 25 to about 30 parts by weight of diol compound, per 100 parts by weight flame retardant composition. The second ingredient of the masterbatch formulation or flame retardant additive package is a Group IIA metal C (6-20) carboxylic acid salt. Group IIA metal carboxylic acid salts containing at least six carbon atoms, as discussed US-A-4,273,691, are particularly effective, and the most preferred Group IIA metal carboxylic acid salt is magnesium stearate. The Group IIA metal carboxylic acid salt may be present in an amount ranging from about 3 to about 30 percent by weight. More preferably such compound is present in an amount ranging from about 5 to about 15 percent by weight and most preferably is present in an amount of from about 8 to about 12 percent by weight. For further information relating to such Group IIA metal carboxylic acid salts, the reader is referred to the teaching of U.S. -A- 4,387,176. The third ingredient of the flame retardant additive is aluminum trihydrate. Aluminum trihydrate is well known in the art as a flame retardant and hence it will not be discussed at length. Generally it may be present in the masterbatch of the present invention in amounts ranging from about 10 to about 60 percent by weight. In a preferred embodiment the aluminum trihydrate is present in an amount ranging from about 30 to about 45 percent by weight, and in the most preferred embodiment the aluminum trihydrate is present in an amount of about 35 to about 40 percent by weight. The fourth and last essential ingredient of the flame retardant masterbatch of the present invention is an organic halide, most preferably decabromodiphenyl oxide, DBDPO. Other organic halides which are believed to be suitable for practicing the present invention are Dechlorane Plus (COD - di HEX); pentabromochlorocyclohexane (PBCCH); hexabromocyclododecane (HBCD); 2,3,4,5,6-pentabromoethylbenzene (PBEB); and 1,2-bis-(2,4,6-tribromophenoxy)ethane (BTBPE). In its broadest aspects the organo halide, which preferably is decabromodiphenyl oxide, is present in an amount ranging from about 10 to about 50 percent by weight. In a more preferred embodiment such organic halide is present in an amount ranging from about 20 to about 35 percent by weight, and in the most preferred embodiment the organic halide, especially DBDPO, is present in an amount ranging from about 25 to about 30 percent by weight. Masterbatch formulations within the scope of the present invention may, of course, contain other ingredients depending upon the end use of the nylon plastic intended by the artisan. Thus, the masterbatch blend may include various fillers such as talc, clay, calcium carbonate, fumed silica, wollastonite and the like. Other suitable fillers will be obvious to those skilled in the art. Another optional ingredient which may be utilized in the flame retardant additive of the present invention is a class of materials referred to as silicone MQ resins. MQ resins are typically comprised of monofunctional (M) siloxy units of the formula R₃SiO 0.5 and tetrafunctional (Q) siloxy units of the formula SiO₂ and having a specified ratio of M to Q units. One effective silicone resin is polytrimethylsilylsilicate which can have a ratio of, approximately, 0.3 to 4.0 M units per Q unit. For further information relating to suitable silicone resins the reader is again referred to, U.S. -A-4,387,176. Other useful optional additives will be obvious to the skilled artisan which are intended to be included within the scope of the instant invention so long as they are used in combination with the four essential ingredients disclosed hereinabove. In a second aspect of the present invention, a novel flame resistant nylon plastic composition is provided which comprises from about 10 to about 50 percent by weight of the foregoing flame retardant additive or masterbatch formulation and from about 50 to about 90 percent by weight of nylon material. It is believed that the masterbatch formulation of the instant invention will be suitable for rendering any nylon material flame retardant, however, it is particularly preferred that such masterbatch be employed in combination with the nylon plastics identified as nylon-6, nylon-6,6, nylon-6,10, nylon-11 and nylon-12. More preferably the nylon plastic used to practice the present invention is nylon-6 or nylon-11 and most preferably it is nylon-11. Preferably there is present from about 25 to about 45 percent by weight of masterbatch formulation and about 55 to 75 percent by weight of nylon material. Most preferably there is present from about 35 to about 40 percent by weight of masterbatch formulation and about 60 to about 65 percent by weight of nylon material. Based on the foregoing, those skilled in the art will be able to adapt and optimize, without undue experimentation, the flame retardant compositions of the present invention. In the practice of the present invention, the flame retardant additive or masterbatch formulation can be made by mixing together (i) diphenylsilane diol; 1,1,3,3-tetraphenyldisiloxanediol; 1,1,3,3,5,5-hexaphenyltrisiloxanediol, or mixtures thereof, (ii) a Group IIA metal C 6-20 -carboxylic acid salt, (iii) aluminum trihydrate and (iv) an organic halide. Mixing may be effected by means of any conventional compounding or blending apparatus, such as for example, a Banbury mixer or a mixing extruder. The particular order of addition of the constituents does not appear to be critical and, in fact, all of the ingredients can be placed in the same container prior to mixing. Of course, the flame resistant nylon plastic compositions of the present invention can be molded, extruded or the like, in accordance with methods well known to those skilled in the art. In order that those skilled in the art will be better able to practice the invention, the following examples are given by way of illustration and not by way of limitation. All parts are by weight unless otherwise specified. EXAMPLES All samples were prepared by boiling in water for 2 hours and then equilibrating at ambient conditions for 2 days prior to testing. Example 1 A nylon material obtained from American Hoechst Corporation, designated as Grade 513 and described as nylon-6 (indicating that it was manufactured from caprolactam) was tested for Gardner Impact and flammability under UL-94 test conditions with the following results: This shows that nylon-6 alone is not a flame resistant composition. Example 2 In this example, 125 parts nylon-6 was blended with 13.6 parts diphenylsilanediol, 7.0 parts of an MQ resin, 6.8 parts magnesium stearate, 27.4 parts aluminum trihydrate, and 20.6 parts decabromodiphenyl oxide with the following results: This example illustrates an effective flame resistant nylon composition. Example 3 In this example a sample identical to that of Example 2 was prepared except that the MQ resin was excluded. The following results were obtained: This example also illustrates an effective nylon flame resistant composition and shows that the presence of MQ resin is not critical. Example 4 Again, there was utilized 125 parts nylon-6 as in Example 1 which were blended with 13.6 parts 1,1,3,3,5,5-hexaphenyldisiloxanediol, 7.0 parts MQ-resin, 6.8 parts magnesium stearate, 27.4 parts aluminum trihydrate and 20.6 parts decabromodiphenyl oxide. The results were as follows: This example illustrates a successful flame resistant nylon composition which utilizes a low molecular weight siloxane diol in place of the diphenylsilanediol of Examples 2 and 3. Example 5 This example is identical to Example 4 except that an MQ resin is not included. The following results were obtained: This example also shows a nylon plastic composition having excellent flame resistance and, again, shows that an MQ resin is not an essential ingredient. Example 6 (comparative example) In this example 125 parts by weight nylon-11 (sold commercially as Rilsan grade BESNO-TL nylon-11) was tested for Gardner Impact, Notched Izod Impact, and flammability under UL-94 test conditions with the following results: This example shows that nylon-11 is not a flame resistant composition. Example 7 In this example, 125 parts Rilsan grade BESNO-TL nylon material of the type employed in Example 6 was blended with the following masterbatch formulation prior to molding and testing for Gardner Impact, Notched Izod Impact, and flammability under UL-94 test conditions: 20.6 parts diphenylsilanediol, 6.8 parts magnesium stearate, 27.4 parts aluminum trihydrate, and 20.6 parts decabromodiphenyl oxide. The test results were as follows: This example shows that the flame retardant additive of the present invention is particularly effective with nylon-11 as not only does it result in a UL-94 rating of V-O, but also provides improved Notched Izod Impact resistance and comparable Gardner Impact results. Example 8 (comparative example) A commercially available flame resistant nylon-11 material sold by Rilsan Corp. as Grade RDG-68 was tested in the same manner as the flame retardant nylon-11 composition of Example 7 for comparative purposes with the following results: This example illustrates a nylon-11 compound having a UL-94 V-O rating which extinguishes rapidly but which has inferior qualities with respect to Gardner Impact and Notched Izod Impact. Example 9 (comparative example) In order to show the importance of diphenylsilane diol or low molecular weight phenyl substituted siloxane diol, a composition was prepared as follows: 145.6 parts BESNO-TL nylon-11, 6.8 parts magnesium stearate, 27.4 parts aluminum trihydrate and 20.6 parts decabromodiphenyl oxide. This sample was only tested for flammability under UL-94 test conditions with the following results: Compression Molded Sample: 7.8 sec. flaming drops Injection Molded Sample 3.3 Sec. flaming drops Each sample therefore received a UL-94 rating of V-II. This example thus shows that the effect of the diphenylsilanediol or low molecular weight phenyl substituted siloxane diol is to eliminate flaming drops.

Claims: A flame retardant composition comprising: (a) 50 to 90 percent by weight of one or more nylon materials, and (b) 10 to 50 percent by weight of a composition effective for imparting flame resistance comprising: (i) 20 to 75 percent by weight based on (b) of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol, 1,1,3,3,5,5,-hexaphenyltrisiloxanediol, or mixtures thereof; (ii) 3 to 30 percent by weight based on (b) of Group IIA metal C 6-20 -carboxylic acid salt; (iii) 10 to 60 percent by weight based on (b) of aluminum trihydrate; and (iv) 10 to 50 percent by weight based on (b) of organic halide. A composition as in Claim 1 wherein said nylon material is nylon-6, nylon-6,6, nylon-6,10, nylon-11, nylon-12 or mixtures thereof. A composition as in Claim 1 wherein said nylon material is nylon-6, nylon-11, or mixture thereof. A composition as in Claim 1 wherein said nylon material is nylon-11. A composition as in Claim 1 wherein there is present 55 to 75 percent by weight of said one or more nylon materials and 25 to 45 percent by weight of said composition effective for imparting flame resistance. A composition as in Claim 1 wherein there is present 60 to 65 percent by weight of said one or more nylon materials and 35 to 40 percent by weight of said composition effective for imparting flame resistance. A composition as in Claims 1, 5 or 6 wherein said composition effective for imparting flame resistance comprises: (i) 25 to 45 percent by weight based on (b) of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol, 1,1,3,3,5,5-hexaphenyltrisiloxanediol or mixtures thereof; (ii) 5 to 15 percent by weight based on (b) of Group IIA metal C 6-20 -carboxylic acid salt; (iii) 30 to 45 percent by weight based on (b) of aluminium trihydrate; and (iv) 20 to 35 percent by weight based on (b) of organic halide. A composition as in Claims 1, 5 or 6 wherein said composition effective for imparting flame resistance comprises: (i) 25 to 30 percent by weight based on (b) of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol, 1,1,3,3,5,5-hexaphenyltrisiloxanediol or mixtures thereof; (ii) 8 to 12 percent by weight based on (b) of Group IIA metal C 6-20 -carboxylic acid salt; (iii) 35 to 40 percent by weight based on (b) of aluminum trihydrate; and (iv) 25 to 30 percent by weight based on (b) of organic halide. A composition as in Claim 1, 7 or 8 wherein said (b)(ii) Group IIA metal carboxylic acid salt is magnesium stearate. A composition as in Claim 1, 7, or 8 wherein said (b)(iv) organic halide is decabromodiphenyl oxide. A composition as in Claim 1, 7 or 8 wherein (b)(i) is selected from the group consisting of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol and 1,1,3,3,5,5-hexaphenyltrisiloxanediol; (b) (ii) is magnesium stearate; and (b)(iv) decabromodiphenyl oxide. A process for providing a flame retardant composition as defined in claim 1 comprising combining ingredients (a) to (b)(iv) of Claim 1. A process as in Claim 12 wherein said nylon material is nylon-6, nylon-6,6, nylon-6,10, nylon-11, nylon-12 or mixture thereof. A process as in Claim 12, wherein there are combined 55 to 75 percent by weight of said one or more nylon materials and 25 to 45 percent by weight of said composition effective for imparting flame resistance. A process as in Claim 12 wherein there are combined 60 to 65 percent by weight of said one or more nylon materials and 35 to 40 percent by weight of said composition effective for imparting flame resistance. A process as in Claims 12, 14 or 15 for providing a composition as defined in claim 7 comprising combining ingredients (i), (ii), (iii) and (iv) of claim 7. A process as in Claims 12, 14 or 15 for providing a composition as defined in claim 8 comprising combining ingredients (i), (ii), (iii) and (iv) of claim 8. A process as in Claim 12 further comprising molding said flame retardant composition. A process as in Claim 12 further comprising extruding said flame retardant composition. A process as in Claim 12 further comprising coating said flame retardant composition on a substrate. A composition effective for improving the flame retardant properties of nylon materials comprising: (a) 20 to 75 percent by weight of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol, 1,1,3,3,5,5-hexaphenyltrisiloxanediol or mixtures thereof; (b) 3 to 30 percent by weight of Group IIA metal C 6-20 -carboxylic acid salt; (c) 10 to 60 percent by weight of aluminum trihydrate; and (d) 10 to 50 percent by weight of organic halide, each based on the sum of (a), (b), (c) and (d). A composition as in Claim 21 comprising: (a) 25 to 45 percent by weight of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol, 1,1,3,3,5,5-hexaphenyltrisiloxanediol or mixtures thereof; (b) 5 to 15 percent by weight of Group IIA metal C 6-20 -carboxylic acid salt; (c) 30 to 45 percent by weight of aluminum trihydrate; and (d) 20 to 35 percent by weight of organic halide. A composition as in Claim 21 comprising: (a) 25 to 30 percent by weight of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol, 1,1,3,3,5,5-hexaphenyltrisiloxanediol or mixtures thereof; (b) 8 to 12 percent by weight of Group IIA metal C 6-20 -carboxylic acid salt; (c) 35 to 40 percent by weight of aluminum trihydrate; and (d) 25 to 30 percent by weight of organic halide. A composition as in Claims 21, 22 or 23 wherein said Group IIA metal carboxylic acid salt is magnesium stearate. A composition as in Claims 21, 22 or 23 wherein said organic halide is decabromodiphenyl oxide. A composition as in Claims 21, 22, 23 wherein (a) is selected from the group consisting of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol and 1,1,3,3,5,5,-hexaphenyltrisiloxandiol; (b) is magnesium stearate; and (d) is decabromodiphenyl oxide. A process for providing a composition as defined in Claim 21 effective for rendering nylon flame retardant, comprising combining ingredients (a), (b), (c) and (d) of Claim 21. A process as in Claim 27 for providing a composition as defined in Claim 22 comprising combining ingredients (a), (b), (c) and (d) of Claim 22. A process as in Claim 27 for providing a composition as defined in Claim 23 comprising combining ingredients (a), (b), (c) and (d) of Claim 23. A process as in Claims 27, 28 or 29 wherein said Group IIA metal carboxylic acid salt is magnesium stearate. A process as in Claims 27, 28 or 29 wherein said organic halide is decabromodiphenyl oxide. A process as in Claims 27, 28, 29 wherein (a) is selected from the group consisting of diphenylsilanediol, 1,1,3,3-tetraphenyldisiloxanediol and 1,1,3,3,5,5-hexaphenyltrisiloxanediol; (b) is magnesium stearate; and (d) is decabromodiphenyl oxide.

Inventors: ASHBY, BRUCE ALLAN
Applicants: GENERAL ELECTRIC COMPANY
Application year: 1985
Main classification: C08L77
IPC codes: C08K3, C09K21, C08L77, C08K5, C08K13