FLAME-RETARDANT RESIN COMPOSITION

Abstract: A flame-retardant resin composition comprises a ther­ moplastic polyester, a flame retardant containing an or­ ganic halide compound in an amount required for providing flame-retardancy and an alkoxidesilane compound in an amount required for providing thermostability. The flame-­ retardant resin composition has a high strength and is ex­ cellent in the thermal stability.

Description: This invention relates to a flame-retardant resin composition and, more specifically, it relates to a flame-retardant resin composition comprising a thermoplastic polyester which is excellent in mechanical property and thermal stability. Flame-retardant resin compositions comprising thermoplastic polyesters using organic halide compounds as the main ingredient have involved a problem in their thermal stability. Particularly, flame-retardant resin compositions composed of polyethylene terephthalate excellent in heat-resistance have a relatively high molding temperature and exhibit remarkable heat degradation upon molding. A flame retardant resin composition comprising a thermoplastic polyester having an improved thermal stability is disclosed, for example, in JP-A-195142/82. In this composition, the surface of antimony trioxide added for providing flame-retarding property is treated with an alkoxysilane to form a cover which is inactive to the hydrolysis of the thermoplastic polyester thereby improving the thermostability. However, as can be seen from the examples of JP-A-195142/82, the mechanical strength, particularly, the tensile strength of the molding product is relatively low and not yet sufficiently satisfactory in specific uses. JP-A-2357/82 describes that covered antimony oxide has no thermal stability of commercial value. JP-A-2357/82 describes a specific composition excellent in the thermal stability. According to the specification thereof, when a particular substance for improving the crystallizing rate and an antimonate salt of a metal belonging to group I, II and VIII of the Periodic Table are used together in a flame-retardant, they do not give adverse effects on the thermal stability and improve the flame-retardancy. Generally, since crystallization stimulators tend to reduce the mechanical strength of the resin composition, their use is limited. Further, the possible range of applying this technique is limited since the effect can only be obtained in the combined use of a specific crystallization stimulator and an antimonate salt. Accordingly, a flame-retardant resin composition composed of a thermoplastic polyester having a relatively high mechanical strength and, at the same time, excellent in the thermal stability has been demanded. EP-A-65 777 describes a flame-retardant resin composition comprising (A) at least one polymer resin consisting of thermoplastic polyesters or thermoplastic polycarbonates, per 100 parts by weight of the polymer resin, (B) 0.1 to 30 parts by weight, as the weight of the halogen element, of an organic halogen compound and (C) 0.1 to 20 parts by weight, as the weight of the antimony element of antimony trioxide treated with an alkoxy silane compound. US-A-4 100 075 relates to finely divided particulate inorganic antimony compounds which are surface-modified with up to about 5% by weight of an organosilane having the formula wherein R₁, R₂ and R₃ are each independently hydrogen, lower alkyl, lower alkenyl, alkoxyalkyl aryl, lower alkylaryl, or lower arylakyl groups and R' is an organo functional group as described. An object of the present invention is to provide a flame-retardant resin composition comprising a thermoplastic polyester having a relatively high mechanical strength and excellent thermal stability in view of the foregoing situations. The object of the present invention can be attained in accordance with the present invention by a flame-retardant resin composition comprising the following ingredients (a) to (d): (a) a thermoplastic polyester, (b) a flame-retardant containing an organic halide compound in an amount of 5 to 50 parts by weight based on 100 parts by weight of the thermoplastic polyester, and (c) an alkoxy silane compound of the general formula (B) wherein each of R₁, R₂, R₃ and R₄ is an alkyl group having 1 to 5 carbon atoms or -C m H 2m -O-C n H 2n+1 wherein m+n is an integer of 5 or less, and X represents -CH=CH₂, -COOCH₃C=CH₂, -NH₂, -NHC₂H₄NH₂, -NHCONH₂ or in an amount of 0.03 to 2.0% by weight of the flame retardant resin (d) and an antimony compound in an amount of 1 to 20 parts by weight based on 100 parts by weight of the thermoplastic polyester. The thermoplastic polyester of the present invention is a saturated linear polyester prepared by reacting a terephthalic acid or a derivative capable of forming esters thereof as an acid ingredient, with a glycol having 2 to 10 carbon atoms or a derivative capable of forming esters thereof as a glycol ingredient. Specifically, there can be mentioned a polyethylene terephthalate, a polypropylene terephthalate, a polybutylene terephthalate, a polytetramethylene terephthalate and a polyhexamethylene terephthalate. These thermoplastic polyesters may be used alone or in admixture of two or more of them. Further, the thermoplastic polyester may contain up to 50% by weight of other ingredients, for example, a diethylene glycol, a polyalkylene oxide, an aromatic diol, etc. Among them, those block copolymers comprising from 1 to 20 parts by weight of a diol represented by the following general formula (A) and from 80 to 99 parts by weight of polyethylene terephthalate are particularly preferred: wherein X represents a divalent connecting group such as a -C(CH₃)2- group, -SO₂- group, -CO- group or -O- group; R represents an alkylene group having 1 to 4 carbon atoms; and n and m each represents an integer from 1 to 15. The intrinsic viscosity of the thermoplastic polyester when measured at 25°C in a mixed solvent of phenol and 1,1,2,2-tetrachloroethane (1 : 1 weight ratio) is preferably from 0.4 to 1.2, more preferably, from 0.5 to 1.0 and most preferably, from 0.55 to 0.70. The flame-retardants referred to in the present invention are those comprising organic halide compound as a main ingredient and an antimony compound. The organic halide compound may include, specifically, tetrabromobisphenol A and oligomers thereof, decabromobiphenyloxide, octabromobiphenyloxide, poly(dibromophenyleneoxide), polystyrene bromide, a condensate of 2 mol of tetrachlorocyclopentadiene and 1 mol of cyclooctadiene, poly(pentabromobenzyl acrylate), a condensate of tetrabromobisphenol A, cyanuric chloride and tribromophenol, hexabromocyclododecane and a condensate of tribromophenol and glycidol and the like. Among them, aromatic halide compounds in which halogen atoms are directly coupled to the aromatic ring are preferably used. As the halogen, bromine or chlorine is preferred. The organic halide compound may be used in a sufficient amount for providing the composition with flame-retardancy, usually, in an amount of from 5 to 50 parts by weight and, preferably, from 10 to 30 parts by weight based on 100 parts by weight of the thermoplastic polyester. The antimony compound used includes, for example, antimony trioxide, antimony pentoxide, sodium antimonate, etc. Sodium antimonate is excellent for improving the thermal stability of the flame-retardant resin composition comprising a thermoplastic polyester. Particularly, sodium antimonate baked at a temperature of not lower than 600°C is preferred. Above all, sodium antimonate having an average particle size of from 2 to 10 µm baked at a temperature of not lower than 600°C is most preferable. The amount of the antimony compound used is 1 to 20 parts by weight, preferably, from 1 to 15 parts by weight and, particularly, from 2 to 10 parts by weight based on 100 parts by weight of the thermoplastic polyester. The alkoxy silane compound is a compound represented by the following general formula (B): wherein each of R₁, R₂, R₃ and R₄ is an alkyl group having 1 to 5 carbon atoms or -C m H 2m -O-C n H 2n+1 wherein m+n is an integer of 5 or less, and X represents -CH=CH₂, -COOCH₃C=CH₂, -NH₂, -NHC₂H₄NH₂, -NHCONH₂ or The compounds in which X contains an amino group or an epoxy group are referred to as an amino silane compound or an epoxy silane compound, respectively. The amount of the alkoxy silane compound to be mixed is preferably from 0.03 to 2.0% by weight, more preferably, from 0.05 to 1% by weight and, most preferably, from 0.1 to 0.5% by weight of the flame-retardant resin. Various methods may be employed for mixing the alkoxy silane compound and other ingredients in the flame-retardant resin composition. For the most simple and general method, the alkoxy silane compound may be added while mixing the thermoplastic polyester and the flame-retardant in a ribbon blender. The alkoxy silane compound has been used as surface treating agent for glass fibers. The thermally stable composition according to the present invention cannot be obtained by merely mixing the glass fibers surface-treated with the alkoxy silane compound, etc., with a flame-retardant resin composition. In the flame-retardant resin composition according to the present invention, 1 to 10 parts by weight of a copolymer of ethylene and α ,β-unsaturated carboxylic acid in which 5 to 50 mol% of carboxylic groups contained in the copolymer are neutralized with an alkali metal may be blended based on 100 parts by weight of the thermoplastic polyester. The copolymers are disclosed in JP-B-26225/70, JP-A-3839/71, 55451/81, for example, copolymers of ethylene and α,β-unsaturated carboxylic acid such as acrylic acid, methacrylic acid, maleic acid or like, wherein the olefin content is at least 50% by weight and 5 to 50 mol% of the carboxylic groups in the copolymer are neutralized with an alkali metal salt. A preferred alkali metal is sodium. The flame-retardant resin composition according to the present invention may further be blended with up to 200 parts by weight of organic or inorganic reinforcing substance or filler, if required, based on 100 parts by weight of the thermoplastic polyester. If the blending amount exceeds 200 parts by weight, molding of the composition becomes difficult and the mechanical strength of the composition is reduced as well. A preferred blending amount is less than 150 parts by weight. The organic or inorganic reinforcing substance or filler are those materials that are added for improving the properties of the molded flame-retardant resin composition in order to, for example, enhance strength and elasticity, for protecting bend, minimizing dimensional change, etc. Specifically, they include fiberous reinforcing material such as glass fibers, carbon fibers, asbestos, aromatic polyamide fibers, silicon carbide fibers, potassium titanate fibers and mineral fibers, as well as calcium carbonate, magnesium carbonate, calcined clay, graphite, mica, talc, glass beads, metal powder, fluoro resin powder and the like. They are used alone or in admixture of two or more of them. In the flame-retardant resin composition according to the present invention, those additives usually employed for thermoplastic flame-retardant polyester resins, for example, anti-oxidants, coloring agents, crystallization stimulators, plasticizers, resins other than polyester and the like may be blended in addition to the above-mentioned ingredients. The composition after mixing the thermoplastic polyester, flame-retardant, alkoxy silane compound and the like can further be formed into a uniform and easily usable flame-retardant composition when further subjected to mixing under melting. The mixing under melting is conveniently carried out by using an extruder. The flame-retardant resin compositions of the present invention are particularly advantageous when used as various applications,such as electronic parts, electric parts, parts for office automation devices, automobile parts, and the like. The present invention will now be described more specifically with referring to Examples and Comparative Examples, but it should be noted that the present invention is no way limited only thereto. In the Examples and Comparative Examples, "parts" and "%" are by weight. EXAMPLE 1 While stirring 4.6 kg of polyethylene terephthalate having an intrinsic viscosity of 0.63 measured at 25°C in a mixed solvent of phenol and 1,1,2,2-tetrachloroethane (1 : 1 weight ratio) and dried to a water content of less than 0.03%, 1.4 kg of polystyrene bromide PYROCHECK 68PB® (trade name of products manufactured by Ferro Corporation), 0.3 kg of sodium antimonate calcined at 700°C, 0.5 kg of a copolymer of ethylene and unsaturated carboxylic acid HI-MIRAN 1707® (trade name of products manufactured by Mitsui-Du Pont Polychemical Co.), 0.2 kg of erucic acid amide, 50 g of a stabilizer IRGANOX 1010® (trade name of products manufactured by Ciba Geigy Limited), 50 g of a stabilizer SEANOX 412S® (trade name of products manufactured by Shipro Kasei Kaisha Co.) in a ribbon blender, 15 g of γ-aminopropyltriethoxy silane (A-1100 manufactured by Nippon Unicar Co.) were added and the stirring was continued further for 5 minutes. The blend was kneaded under melting by using a biaxial extruder PCM-45® manufactured by Ikegai Tekko Co., to obtain a pellet-like resin composition. Glass fibers (Glasslon 03MJ-486A manufactured by Asahi Fiber Glass Co.) were added in an amount of 30% of the composition at the midway of the biaxial extruder. As the temperature condition for the extrusion, a temperature gradient of from 200 to 260°C was created from the hopper side toward the dice side. Other conditions were selected as usual for enabling stable extrusion operation. Then, the pelletized resin was dried at 140°C for 4 hours and then test specimens were prepared by using an injection molding machine (IS-50A manufactured by Toshiba Kikai Co.). As an evaluation method for the thermal stability, mechanical strength was examined at two temperature levels i.e., at normal temperature (270°C) and higher temperature (290°C). The injection molding conditions included a mold temperature of 80°C, cooling time of 30 sec, primary injecting pressure of 495 kg/cm² (4.86·10⁷Pa), secondary injection pressure of 360 kg/cm² (3.53·10⁷Pa) and injection time of 7 seconds. The thermal stability was evaluated by comparing the tensile strength of the products molded at 270°C and 290°C. The results are shown in Table 1. The molded products satisfied the requirements of U.L. (Underwriters Laboratories) Standard 94 as V-0 using a specimen of 1/32 inch (0.794 mm) in thickness. EXAMPLE 2 The procedure of Example 1 was repeated except that 20 g of γ-glycidyloxy propyltrimethoxy silane (A-187, manufactured by Nippon Unicar Co.) were used instead of γ-aminopropyl triethoxy silane. The results are shown in Table 1. The molded products satisfied the requirements of U.L. (Underwriters Laboratories) Standard 94 as V-0 using a specimen of 1/32 inch (0.794 mm) in thickness. COMPARATIVE EXAMPLE 1 In the same manner as in Example 1, a composition without adding γ-aminopropyltriethoxy silane was prepared and evaluated. Other conditions were the same as those in Example 1. The results are shown in Table 1. The molded products also satified the requirements of U.L. Standard 94 as V-0. COMPARATIVE EXAMPLE 2 The procedure of Comparative Example 1 was repeated except that glass fibers prepared according to the following procedure were used. The results are shown in Table 1. Preparation of Glass Fibers 5.0 kg of GLASSLON 03MJ-486A® were charged in a ribbon blender, and a mixture of 25 g of distilled water, 225 g of methanol and 25 g of A-1100® mixed thoroughly was added under stirring and the stirring was further continued for 5 minutes. The resulting mixture was dried at 130°C for 2 hours. As is apparent from the results shown in Table 1, the flame-retardant resin composition according to this invention had high strength and was excellent in thermal stability. The molded products also satisfied the requirements of U.L. Standard 94 as V-0. EXAMPLE 3 The procedure of Example 2 was repeated except that 0.3 kg of antimony trioxide (PATOX-H manufactured by Nippon Seiko Co.) was used instead of sodium antimonate. The results are shown in Table 2. The molded products satisfied the requirements of U.L. (Underwriters Laboratories) Standard 94 as V-0 using a specimen of 1/32 inch (0.794 mm) in thickness. EXAMPLE 4 The procedure of Example 1 was repeated except that 1.3 kg of poly-pentabromobenzyl acrylate (FR-1025 manufactured by Ded C. Bromine Co.) was used instead of PYROCHECK 68PB®. The results are shown in Table 2 below. The molded products satisfied the requirements of U.L. (Underwriters Laboratories) Standard 94 as V-0 using a specimen of 1/32 inch (0.794 mm) in thickness. COMPARATIVE EXAMPLE 3 The procedure of Comparative Example 2 was repeated except that PATOX-H® was used instead of sodium antimonate and FR-1025® instead of PYROCHECK 68PB®, respectively. The results are shown in Table 1 below. The molded products also satisfied the requirements of U.L. Standard 94 as V-0. EXAMPLE 5 The procedure of Example 2 was repeated except that polyethylene terephthalate having an intrinsic viscosity of 0.60, in which an ethylene oxide addition polymer of bisphenol A (bisphenol A to ethylene oxide is 1 : 17; average molecular weight 1000) was block copolymerized by 5% was used instead of polyethylene terephthalate having an intrinsic viscosity of 0.63 stated in Example 1. Other conditions were the same as in Example 2. (1) Tensile strength molded at 270°C (kg/cm²)[x10⁸Pa] 1540 [1.511] (2) Tensile strength molded at 290°C (kg/cm²)[x10⁸Pa] 1530 [1.501] (2) x 100/(1) (%) 99.4 The molded products satisfied the requirements of U.L. (Underwriters Laboratories) Standard 94 as V-0 using a specimen of 1/32 inch (0.794 mm) in thickness. EXAMPLE 6 A mixture of 5.3 kg of polyethylene terephthalate having an intrinsic viscosity of 0.58 when measured at 25°C in a mixed solvent of phenol and 1,1,2,2-tetrachloroethane (1:1 weight ratio) and being dried to a water content of less than 0.03%, 1.4 kg of polydibromophenylene oxide (PO-64P manufactured by Great Lakes Chemical Corporation), 0.3 kg of sodium antimonate, 50 g of IRGANOX 1010® 50 g of SEANOX 412S®, 10 g of A-187® and GLASSLON 03MJ-486A® in an amount of 30% of the composition was processed in the same manner as in Example 1 to obtain a test piece. The results are shown in Table 3 below. The molded products satisfied the requirements of U.L. (Underwriters Laboratories) Standard 94 as V-0 using a specimen of 1/32 inch (0.794 mm) in thickness. EXAMPLE 7 The procedure of Example 6 was repeated except that the polyethylene block copolymer used in Example 5 was used instead of the polyethylene terephthalate of Example 6. The results are shown in Table 3 below. The molded products satisfied the requirements of U.L. (Underwriters Laboratories) Standard 94 as V-0 using a specimen of 1/32 inch (0.794 mm) in thickness. EXAMPLE 8 A resin composition without adding the glass fibers was prepared in the same manner as in Example 2. The results are shown in Table 3 below. The molded products satisfied the requirements of U.L. (Underwriters Laboratories) Standard 94 as V-0 using a specimen of 1/32 inch (0.794 mm) in thickness. COMPARATIVE EXAMPLE 4 A resin composition without adding A-187® was prepared in the same manner as in Example 8. The results are shown in Table 3 below. As has been described above according to the present invention, a flame retardant resin composition having high strength and excellent in the thermal stability can be provided. The mold products also satisfied the requirements of U.L. Standard 94 as V-0.

Claims: A flame-retardant resin composition which comprises a thermoplastic polyester; a flame retardant containing an organic halide compound in an amount of 5 to 50 parts by weight based on 100 parts by weight of the thermoplastic polyester and an alkoxysilane compound of the general formula (B) wherein each of R₁, R₂, R₃ and R₄ is an aklyl group having 1 to S carbon atoms or -C m H 2m -O-C n H 2n+1 wherein m+n is an integer of 5 or less, and X represents -CH=CH₂, -COOCH₃C=CH₂, -NH₂, -NHC₂H₄NH₂, -NHCONH₂ or in an amount of 0.03 to 2.0% by weight of the flame retardant resin and an antimony compound in an amount of 1 to 20 parts by weight based on 100 parts by weight of the thermoplastic polyester. The flame-retardant resin composition as in claim 1, wherein the alkoxysilane compound is an aminosilane compound and/or an epoxysilane compound. The flame-retardant resin composition as in claim 1 or 2, wherein the amount of the alkoxysilane compound is from 0.05 to 1.0% by weight based on the total amount of the flame-retardant resin composition. The flame-retardant resin composition as in claim 1 to 3, wherein the flame-retardant comprises an aromatic compound containing halogen atoms directly bonded to the aromatic ring. The flame-retardant resin composition as in claim 4, wherein the antimony compound is an antimonate salt of a metal belonging to Group I, II and VIII of the Periodic Table. The flame-retardant resin composition as in claim 5, wherein the antimonate salt is sodium antimonate and/or potassium antimonate. The flame-retardant resin composition as in claim 4 to 6, wherein the amount of the aromatic compound is from 5 to 50 parts by weight and the amount of the antimony compound is from 1 to 15 parts by weight respectively based on 100 parts by weight of the thermoplastic polyester. The flame-retardant resin composition as in claim 1 to 7, wherein from 1 to 10 parts by weight of a copolymer comprising ethylene and an α,β-unsaturated carboxylic acid in which from 5 to 50 mol% of the carboxylic groups contained in said copolymer are neutralized with an alkali metal are contained based on 100 parts by weight of the thermoplastic polyester. The flame-retardant resin composition as in claim 1, wherein the thermoplastic polyester is polyethylene terephthalate. The flame-retardant resin composition as in claim 1, wherein the thermoplastic polyester is a block copolymer of polyethylene terephthalate and a compound represented by the following general formula (A): wherein X represents one of the divalent connecting groups -C(CH₃)₂-, -SO₂- -CO-, or -O-; R represents an alkylene group having 1 to 4 carbon atoms; and n and m each represents an integer from 1 to 15; and the content of the segments represented by the general formula (A) in said copolymer is from 1 to 20 parts by weight. The flame-retardant resin composition as in claim 1 to 10, which contains less than 200 parts by weight of organic and/or inorganic reinforcing substances and/or filler based on 100 parts by weight of the thermoplastic polyester.

Inventors: MIYASHITA, SHUNITSU, MOGAMI, KENJI
Applicants: KANEGAFUCHI KAGAKU KOGYO KABUSHIKI KAISHA
Application year: 1986
Main classification: C08K5
IPC codes: C08K5, C08L67, C08L33, C08L101, C08K9, C08L1, H05K1, C08K3, C08L27, C08L77, C08L23