Fire retardant thermoplastic fluoropolymer compositions

Abstract: Thermoplastic fluoropolymer compositions, flexible, without whitening, comprising: I) ETFE or ECTFE fluoropolymers modified with hydrogenated monomers; II) one or more hydrogenated plasticizers; III) one or more inorganic fire retardants; IV) optionally other ingredients such as fillers, smoke retarders, intumescent agents, pigments, lubricants, organic fire retardants and thermal stabilizers.

Description: The present invention relates to thermoplastic fluoropolymer compositions for the plenum wire insulation and cable jacketing applications, that show a high time to ignition, a low smoke and heat release when put in contact with a heat source as for example in the Cone Calorimeter (see the ASTM E1354 test). More in particular the present invention relates to thermoplastic compositions of fluoropolymers of ethylene with tetrafluoroethylene (ETFE) and/or chlorotrifluoroethylene (ECTFE), modified with one or more hydrogenated monomers. The copolymers of ethylene and a fluorinated monomer such as tetrafluoroethylene (TFE), chlorotrifluoroethylene (CTFE), or both, are known in the art. It is also known the possibility to modify them with fluorinated unsaturated monomers in an amount between 0.1 and 10% by moles. For example we mention the (per)fluoroalkylvinylethers in which the alkyl group has at least two carbon atoms, in particular the perfluoropropylvinylether (see USP 3,624,250). Other possible comonomers have the formula R'-CH=CH 2 , where R' is a perfluoroalkyl or a perfluoroalkoxy-perfluoroalkyl (see EP 185,241, EP 185,242). The above mentioned ETFE and ECTFE copolymers non modified with fluoroolefins have poor affinity with hydrogenated substances, these being polymers or high molecular weight compounds (for example plasticizers). In EP 728,776 a special fluoroolefin able to copolymerize with fluorinated olefins giving for example a modified ETFE, is disclosed. This polymer shows good affinity with hydrogenated polymers, in particular with aromatic polyesters. In general the syntheses of special fluoroolefins are complex and therefore they are used as comonomers in ethylene fluoropolymers only when high performances are required. For example good chemical resistance combined with excellent mechanical properties at high temperatures (150°-200°C). The preparation of fluoropolymers blended with one or more plasticizers to make the fluoropolymers flexible and usable in the cable industry has a particular industrial interest. These polymers must be characterized by the absence of the whitening phenomenon when the cable is bent. The whitening effect must be avoided because it visually represents the plastic deformation of the material, and due to this it cannot recover the initial state. The electrical properties required for this material are fully satisfied by the ECTFE which unfortunately has a high elastic modulus at room temperature, in general higher than 1500 MPa and therefore it is not flexible. In addition the ECTFE has a stress-strain curve at room temperature characterized by a necking at yield that makes it sensitive to the whitening effect on the bent cable. The elastic modulus of ECTFE can be lowered by adding plasticizers, but in any case the material suffers from the whitening effect. The Applicant, in order to overcome this problem, as disclosed in EP 866,079, has proposed the use of ETFE or ECTFE type fluoropolymers modified with hydrogenated monomers blended with plasticizers, having high flexibility and that do not show the whitening phenomenon. However for safety reasons these flexible cables must show a high time to ignition, a low smoke and heat release when put in contact with a heat source, as for example in the Cone Calorimeter (see the ASTM E1354 test). Unfortunately the presence of plasticizers increases the smoke and heat release. The Applicant has found that when using fire retardants treated with dispersing agents in the polymers compounded with plasticizers, it is possible to obtain flexible compositions having the following combination of properties: good mechanical properties, absence of the whitening effect, decrease of smoke and heat release when tested in a Cone Calorimeter according to the ASTM E1354 tests. An object of the present invention is a thermoplastic composition flexible without whitening, comprising: I) ETFE or ECTFE fluoropolymers modified with hydrogenated monomers; II) one or more hydrogenated plasticizers; III) one or more inorganic fire retardants treated with dispersing agents. More in particular the component I) of the compositions of the invention is a copolymer consisting of: (a) at least 10, preferably from 35 to 55%, by moles of ethylene, (b) at least 30%, preferably from 45 to 65%, by moles of a fluorinated monomer selected from tetrafluoroethylene and/or chlorotrifluoroethylene, (c) from 0.1 to 30%, preferably from 1 to 15%, by moles of a monomer of formula: CH 2 =CH-(CH 2 ) n -R 1 where R 1 = -OR 2 , -(O) t CO(O) p R 2 wherein t and p are integers equal to 0 or 1 and R 2 is an alkyl radical from 1 to 10 carbon atoms optionally containing one or more hydroxy functional groups, n is an integer in the range 0-5, (a)+(b)+c is 100% by moles. The preferred comonomers (c) are for example selected from the following classes: 1) Acrylic monomers of formula: CH 2 =CH-CO-O-R 2 wherein R 2 has the aforesaid meaning. For example ethylacrylate, n-butylacrylate, acrylic acid, hydroxyethylacrylate, hydroxypropylacrylate and (hydroxy)ethylhexylacrylate can be mentioned. 2) Vinylether monomers of formula: CH 2 =CH-O-R 2 wherein R 2 has the aforesaid meaning. For example propylvinylether, cyclohexylvinylether, and vinyl-4-hydroxybutylether can be mentioned. 3) Vinyl esters of a carboxylic acid of formula: CH 2 =CH-O-CO-R 2 wherein R 2 has the aforesaid meaning. For example vinylacetate, vinylpropionate and vinyl-2-ethylhexanoate can be mentioned. 4) Unsaturated carboxylic acids of formula: CH 2 =CH-(CH 2 ) n -COOH wherein n has the aforesaid meaning. For instance vinylacetic acid. The most preferred monomer of formula (I) is n-butyl acrylate. Components II) are hydrogenated plasticizers well known in the art and used in the hydrogenated (co)polymers, from 1 to 20% by weight, preferably from 5 to 10% by weight referred to the total weight of the composition. Examples of plasticizers, not limitative for the present invention, are: 2-ethylhexyldiphenylphosphate, neopentyl glycoldibenzoate, tricresylphosphate, tetrabromophtalate ester, tri-n-hexyl-trimellitate, ethylene glycol monostearate, acetyltri-n-hexyl citrate acetyltri-n-butyl citrate (Citroflex® A4) and tributyl trimellitate. Components III) are the inorganic fire retardants used in amounts from 0.2 to 35% by weight, preferably from 1 to 15% by weight, referred to the total weight of the composition. The fire retardants are well known in the art of hydrogenated (co) polymers. We can mention, ammonium phosphate, aluminum oxide, aluminum oxide tri-hydrate, antimony oxides, molybdenum oxide, tin oxalates, borax, zinc borate (Firebrake® ZB), magnesium hydroxide, or hydroxide mixtures such as Zn(OH) 2 and Sn(OH) 4 e.g. ZnSn(OH) 6 ). The Applicant has surprisingly found that the use of inorganic fire retardants treated with dispersing agents with respect to the simple addition of inorganic fire retardants to the plasticized ETFE or ECTFE fluoropolymer type modified with monomers of formula (I), leads to unexpected increase of the time to ignition and to a substantial decrease of smoke and heat release according to the ASTM E1354 test run in a Cone Calorimeter. The inorganic fire retardants are treated with dispersing agents in amounts ranging from 0.01 to 10% by weight, more preferably from 0.1 to 5% by weight. The preferred dispersing agents according to the present invention have formula: (R 3 ) 4-m A(X) m wherein A is Si or Ti; R 3 is a C 1 -C 15 alkyl and/or aryl radical. The R 3 radical can contain O, N, S, or halogens such as Cl; functional groups such as amine, epoxide, thio, hydroxide, carboxyl and carboxylate; m is 2 or 3; X is an alkoxy group OR 4 in which R 4 is a C 1 -C 5 linear or branched alkyl radical, preferably R 4 is methyl or ethyl. When A is equal to Si preferably m = 3 and R 4 is methyl or ethyl. For example we can mention: vinyltriethoxysilane, 3-aminopropyltriethoxysilane, 3-chloroisobutyltriethoxysilane, 3-mercaptopropyltriethoxysilane, octyltriethoxysilane, bis-acetylacetonate diisopropoxytitanate. The addition of the dispersing agents to the inorganic fire retardants and to the inorganic component IV) is preferably carried out at room temperature and followed by a thermal treatment at about 100°C for one or more hours. The water required for the hydrolysis of the dispersing agents comes from the reaction medium and/or from the solution containing one or more dispersing agents, or from the environment. The following examples are given for illustrative purposes but are not limitative of the present invention. In Table 1 the tests have been carried out according to the ASTM E1354 method for the time to ignition; heat and visible smoke release rates for materials and products using an Oxygen Consumption Calorimeter; Radiant Heat Flux 90 Kw/m 2 ; sample weight 50 g; horizontal sample direction. EXAMPLE 1 (Referential) In an enamelled autoclave equipped with baffles and stirrer working at 450 rpm in Hastelloy C, 7 1 of demineralized water, 15.5 g of chloroform, 10 g of n-butylacrylate and 2 kg of chlorotrifluoroethylene were introduced. The temperature reaction was set and maintained at 15°C. Then ethylene was charged up to a pressure of 8.2 absolute bars. In the autoclave the radical initiator was then continuously introduced during the whole polymerization time, under the form of a solution, maintained at -17°C, of trichloroacetylperoxide (TCAP) in isooctane with titre of 0.1 g TCAP/ml. In addition 10 g of n-butylacrylate were charged to the reactor at consumption of 20, 40, 60, 80, 100, 120, 140, 160 and 180 g of ethylene. The pressure was maintained constant for the whole polymerization by continuously feeding ethylene in the reactor up to a consumption of 200 g; the total amount of initiator solution was of 210 ml. The polymerization lasted 405 minutes. Then the polymer produced was dried at 120°C for about 16 hours. The total dry weight was of 1530 g. The polymer was then compounded with MARK-260® 0.45% by weight and Aclyn-316® 0.15% by weight both mainly used as thermal stabilizers. Some characteristics of this polymer (defined Polymer A) are the following: the Melt Flow Index (M.I.) according to ASTM 3275-89 method is of 9 g/10'; the second melting point (T mII ) determined by Differential Scanning Calorimetry (DSC) is 190°C and the molar composition obtained by carbon elemental analysis and by material balance is ethylene 40% by moles, chlorotrifluoroethylene 55% by moles and n-butylacrylate 5% by moles. EXAMPLE 2 (comparative) The polymer powder A has been blended with Citroflex® A4 in an amount equal to 7% by weight based on the blend. Then the blend has been pelletized in a twin-screw extruder. This compound has been tested in a Cone Calorimeter according to the ASTM E1354 method. Table 1 reports time to ignition, peak heat release rate, total heat released and average extinction coefficient related to the smoke for a sample of 50 g. EXAMPLE 3 (comparative) The polymer powder A blended with Citroflex® A4 as in Example 2 has been compounded with zinc borate (Firebrake® ZB 500) 5% by weight and mica 1% by weight based on the total weight. Then the blend has been pelletized in a twin-screw extruder. This compound has been tested in a Cone Calorimeter according to the ASTM E1354 method. Table 1 reports time to ignition, peak heat release rate, total heat released and average extinction coefficient related to the smoke for a sample of 50 g. EXAMPLE 4 As in Example 3 except that zinc borate and mica are blended with 2% by weight of water-borne 3-aminopropyltriethoxysilane, and then thermally treatment at 100°C for two hours. Then the blend has been pelletized in a twin-screw extruder. This compound has been tested in a Cone Calorimeter according to the ASTM E1354 method. Table 1 reports time to ignition, peak heat release rate, total heat released and average extinction coefficient related to the smoke for a sample of 50 g. EXAMPLE 5 As in Example 3 except that zinc borate and mica are blended with 2% by weight of a solution formed by 75% by weight of bisacetylacetonate diisopropoxytitanate and 25% by weight of isopropanol, and then thermally treated at 100°C for two hours. Then the blend has been pelletized in a twin-screw extruder. This compound was tested in a Cone Calorimeter according to the ASTM E1354 method. Table 1 reports time to ignition, peak heat release rate, total heat released and average extinction coefficient related to the smoke for a sample of 50 g by weight. The mechanical properties at 23°C according to the ASTM D1708 test of compression moulded specimen of the compound are shown in Table 2. EXAMPLE 6 As in Example 3, except that zinc borate and mica are blended with 2% by weight of a solution formed by 75% by weight of bisacetylacetonate diisopropoxytitanate and 25% by weight of isopropanol and with 2% by weight of water-borne 3-aminopropyltriethyoxysilane, and then thermally treated at 100°C for two hours. Furthermore, 1% by weight of PTFE (POL-YMIST®) has been added to the compound and then pelletized in a twin-screw extruder. This compound has been tested in a Cone Calorimeter according to the ASTM E1354 method. Table 1 reports time to ignition, peak heat release rate, total heat released and average extinction coefficient related to the smoke for a sample of 50 g. The mechanical properties at 23°C according to the ASTM D1708 test of compression moulded specimen of the compound are shown in Table 2. From Tables 1 and 2 it can be observed that the compositions of the invention are characterized by having good mechanical properties, they are flexible, they do not show the whitening effect and they have excellent flame-retardant and smoke-suppressed properties. Mechanical properties 23°C Example 5 Polymer A (P,TiFR) Example 6 Polymer A (P,L,SiTiFR) Elastic modulus (MPa) 270 280 Stress at yield (MPa) 10 10 Elongation at yield (%) Stress at break (MPa) 27 28 Elongation at break (%) 260 270

Claims: Thermoplastic fluoropolymer compositions, flexible without whitening, comprising: I) a copolymer consisting of: (a) at least 10%, by moles of ethylene, (b) at least 30%, by moles, of a fluorinated monomer selected from tetrafluoroethylene and/or chlorotrifluoroethylene, (c) from 0.1 to 30%, by moles, of a monomer of formula CH 2 =CH-(CH 2 ) n -R 1 where R 1 = -OR 2 , -(O) t CO(O) p R 2 wherein t and p are individually integers equal to 0 or 1, n is an integer in the range 0-5; R 2 is an alkyl radical having from 1 to 10 carbon atoms, optionally containing one or more hydroxy functional groups, provided that (a)+ (b)+ (c) is 100 % by moles; II) 1-20% by weight of a hydrogenated plasticizer: III) 0.2-35% by weight of an inorganic fire retardant selected from inorganic phosphates, metal oxides, tin oxalates, boron compounds and metal hydroxides treated with 0.01 to 10% by weight of a compound having the formula (R 3 ) 4-m A(X) m in which R 3 is a C 1 -C 15 alkyl or aryl radical optionally containing O, N, S, halogen or a group selected from amine, epoxide, thio, hydroxide, carboxyl, carboxylate; m is 2 or 3; X is an alkoxy -OR 4 , wherein R 4 is C 1 -C 5 alkyl; A is Si or Ti, provided that when A is Si, m is 3 and R 4 is methyl or ethyl, the % by weight of components II) and III) are referred to the total weight of the composition. Compositions according to claim 1, wherein the comonomer c) is selected from the group consisting of: ethylacrylate, n-butylacrylate, acrylic acid, hydroxyethylacrylate, hydroxypropylacrylate, (hydroxy)ethylhexylacrylate; propylvinylether, cyclohexylvinylether, vinyl-4-hydroxybutylether; vinylacetate, vinylpropionate, vinyl-2-ethylhexanoate and vinylacetic acid. Compositions according to any of claims 1 or 2, wherein the component III) is selected from the group consisting of: of ammonium phosphate, aluminum oxide, aluminum oxide tri-hydrate, antimonium oxides, molybdenum oxide, tin oxalates, borax, zinc borate, magnesium hydroxide, a mixture of Zn(OH) 2 and Sn(OH) 4 . Compositions according to any of claims 1 to 3, wherein the compound of formula (II) is selected from the group consisting of vinyltriethoxysilane, 3-aminopropyltriethoxysilane, 3-chloroisobutyltriethoxysilane, 3-mercaptopropyltriethoxysilane, octyltriethoxysilane, or bis-acetylacetonate diisopropoxytitanate. Compositions according to claims 1 to 4, wherein component II) is selected from the group consisting of 2-ethylhexyldiphenylphosphate, neopentyl glycoldibenzoate, tricresylphosphate, tetrabromophthalic ester, tri-n-hexyltrimellitate, ethylene glycol monostearate, acetyl tri-n-hexyl citrate, acetyl tri-n-butyl citrate, tributyl trimellitate.

Inventors: ABUSLEME JULIO A, STANITIS GARY, ZOLOTNITSKY MIKHAIL, ABUSLEME, JULIO A., STANITIS, GARY, ZOLOTNITSKY, MIKHAIL
Applicants: SOLVAY SOLEXIS SPA, SOLVAY SOLEXIS S.P.A.
Application year: 1998
Main classification: C08K13
IPC codes: C08K9, C08K5, C08L27, C08K3, C08L23