CN103068920A - 阻燃剂聚(对苯二甲酸丙二醇酯)组合物以及由其制成的制品 - Google Patents
阻燃剂聚(对苯二甲酸丙二醇酯)组合物以及由其制成的制品 Download PDFInfo
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Abstract
本发明提供了具有改善的阻燃性的聚(对苯二甲酸丙二醇酯)组合物,以及由其制成的制品。所述组合物能够用于制造毯,所述毯适于安装在需要阻燃性的地方。
Description
技术领域
本发明涉及具有改善的阻燃性的聚(对苯二甲酸丙二醇酯)组合物以及由所述组合物制成的制品。
背景技术
聚(对苯二甲酸丙二醇酯)(PTT)在多种需要阻燃性的应用中都是潜在可用的。然而,对于PTT仍然需要改善阻燃性。具体地,希望在毯中提供PTT的改善的辐射板性能(radiant panel performance),从而可获得本领域已知的1级方块毯(>0.45watts/cm2)。
发明内容
本发明的一个方面为聚(对苯二甲酸丙二醇酯)基组合物,包含:(a)基于组合物总重量计,约75至约99.9重量%的树脂组分,其中基于所述树脂组分的重量计,所述树脂组分包含至少约70重量%的聚(对苯二甲酸丙二醇酯);以及(b)基于组合物总重量计,约0.1至约25重量%的添加剂包(additive package),其中基于所述组合物总重量计,所述添加剂包包含约0.1至约15重量%的氰尿酸三聚氰胺、焦磷酸三聚氰胺、二乙基次膦酸的锌盐、或它们的共混物。
本发明的另一方面是包含面纤维和预涂层的毯,其中所述面纤维由聚(对苯二甲酸丙二醇酯)基组合物制成,所述组合物包含:(a)基于组合物总重量计,约75至约99.9重量%的树脂组分,其中基于所述树脂组分的重量计,所述树脂组分包含至少约70重量%的聚(对苯二甲酸丙二醇酯);以及(b)基于组合物总重量计,约0.1至约25重量%的添加剂包,其中基于所述组合物总重量计,所述添加剂包包含约0.1至约15重量%的氰尿酸三聚氰胺、焦磷酸三聚氰胺、二乙基次膦酸的锌盐、或它们的共混物,并且所述预涂层包含选自三水合铝(ATH)和氢氧化镁的阻燃添加剂。
附图说明
图1示出临界辐射光通量相对于方块毯的纤维面重量的散点图,所述方块毯使用本文所公开的聚(对苯二甲酸丙二醇酯)基组合物制成。拟合线图示出在纤维中不含任何阻燃剂的情况下预涂层中各种ATH负载的影响。
图2示出临界辐射光通量相对于方块毯的纤维面重量的散点图,所述方块毯使用本文所公开的聚(对苯二甲酸丙二醇酯)基组合物制成。拟合线图示出纤维中阻燃添加剂以及预涂层中ATH的影响。
图3示出临界辐射光通量相对于方块毯的纤维面重量的散点图,所述方块毯使用本文所公开的聚(对苯二甲酸丙二醇酯)基组合物制成。拟合线图示出纤维中阻燃添加剂以及预涂层中ATH的影响。
具体实施方式
本文所公开的组合物包含树脂组分,所述树脂组分包含PTT和任选的一种或多种其它聚合物,以及一种或多种阻燃化合物,所述阻燃化合物选自:氰尿酸三聚氰胺、焦磷酸三聚氰胺、二乙基次膦酸的锌盐。可存在于树脂组分中的其它聚合物,包括聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、尼龙、聚丙烯以及它们的共混物。因此,如本文所用,术语“PTT基组合物”旨在涵盖其中树脂组分除PTT之外包含一种或多种其它聚合物的组合物。树脂组分中其它聚合物的量基于树脂组分的总重量可变化并且可以例如为5重量%、10重量%、15重量%、20重量%、或25重量%或更高。在一些优选的实施方案中,其中一种或多种聚合物与PTT一起存在于树脂组分中,基于树脂组分的总重量计,所述树脂组分包含约75至99重量%的PTT以及1至25重量%的其它聚合物。
在一些实施方案中,所述树脂组分包含由生物衍生的1,3-丙二醇制成的聚(对苯二甲酸丙二醇酯)。
已经令人惊奇的发现,可获得包含由聚(对苯二甲酸丙二醇酯)基组合物制成的面纤维以及预涂层的毯,其中所述预涂层包含选自三水合铝和氢氧化镁的阻燃添加剂,所述毯在阻燃性测试中具有预料之外的高且稳定的性能。
在一些实施方案中,树脂组分中所包含的添加剂包除特定阻燃剂之外,还包含一种或多种添加剂例如消光剂(诸如TiO2、硫酸锌或氧化锌)、染料或颜料。所述添加剂包还可包含一种或多种添加剂例如抗氧化剂、残余催化剂、着色剂(例如染料)、稳定剂、填料(例如碳酸钙)、抗菌剂、防静电剂、荧光增白剂、增量剂、加工助剂、和/或其它功能性添加剂,通过称作“成效添加剂(chip additive)”。
可以本领域中常规制备PTT组合物的量使用可用作颜料和/或消光剂的TiO2和其它化合物,例如硫酸锌或氧化锌。例如,对于制备纤维,基于PTT基组合物的总重量计,颜料/消光剂的总量可为约5重量%或更多,而对于其它应用则通常为相对更多的量。可用作颜料和/或消光剂的材料的实例包括TiO2、ZnO、和硫酸锌。在一些实施方案中,优选为TiO2。当用于纤维和薄膜用聚合物中时,TiO2的添加量优选为至少约0.01重量%,并且优选至多为约3重量%,更优选至多为约2重量%(基于总组合物重量计)。
如本文所用,术语“颜料”通常是指本领域中通常称作颜料的那些物质。颜料是通常以干粉形式的物质,其赋予聚合物或由所述聚合物制成的制品(例如,薄片或纤维)颜色。颜料可以是无机或有机的并可以是天然或合成的。一般来讲,颜料是惰性的(即,电中性并且不与聚合物反应)并且基本上不溶于它们所加入的介质中,例如聚(对苯二甲酸丙二醇酯)组合物。然而,颜料还可溶于或部分溶于某些材料中。
优选地将所述树脂组分、阻燃剂和任何其它添加剂熔融共混。优选地在足以形成熔融共混组合物的温度下将树脂组分和一种或多种添加剂(包括阻燃剂)混合并加热。可将所述组合物纺丝成纤维或形成其它成型制品,优选以连续的方式。
可以本领域的技术人员已知的多种不同方式将所述树脂组分和添加剂成型为共混组合物。例如,可将它(a)同时加热和混合,(b)在加热前在分开的装置中预混,或(c)加热然后混合。可通过为此目的设计的常规设备诸如挤出机、混炼机来进行混合、加热和成型。所述温度优选高于每种组分的熔点但低于最低分解温度,并且可对于任何PTT和阻燃添加剂的特定组成而相应地调节。所述温度通常在约180℃至约270℃的范围内。
基于组合物总重量计,阻燃化合物在PTT基组合物中的用量优选为0.1重量%至15重量%。更优选基于PTT-基组合物总重量计,所述量为约0.5至约10重量%,更优选约1至约6重量%,还更优选约2至约6重量%。
在一些实施方案中,还提供包含PTT组合物的制品,诸如纤维、薄膜和模制零件,此类制品具有改善的阻燃剂特性。
还可将所述组合物纺丝成纤维例如膨体连续长丝(BCF)。可将所述BCF制成纱线并形成毯。可使用本领域的技术人员已知的任何方法制备由BCF纱线制成的毯。通常,将多个纱线缆捻在一起以形成毯纱线并且在装置如高压釜中热定型。作为另外一种选择,连续加工例如干燥热定型使用例如Suessen热定型机,或者蒸汽高压釜热定型例如用高压釜,可用于赋予纱线结构稳定性。然后将纱线簇绒成初级背衬,也称作簇绒基底。
可使用本领域的技术人员已知的任何方法制备BCF,例如,如美国专利7013628中所公开,其公开了由带有三角形截面并具有大约1450旦尼尔的总旦尼尔数以及约20.8的旦尼尔/长丝的纤维制成的BCF。纤维韧度在1.5至2.5克/旦尼尔的范围内,并且纤维伸长率在55至75%的范围内。取决于纱线以及由其制成的终产品(例如毯)所期望的特性,所述纤维可具有各种截面形状。例如,所述截面可以是三角形、三叶形、圆形或其它常规用于商品中的形状。由纤维制成的纱线的总旦尼尔数可在1000至3000的范围内,并且旦尼尔/长丝(dpf)可在12至30的范围内。
在一些实施方案中,其中将PTT基组合物用于制备纤维中并将所述纤维用于制备毯,将粘合剂(通常称作预涂层)用于将纤维粘合至簇绒基底。常见预涂层是乳胶衍生的或衍生自热熔性粘合剂。所述乳胶衍生的预涂层或者热熔性粘合剂预涂层包含粘合聚合物树脂并且还可包含填料,例如碳酸钙。在一些情况下,预涂层还可包含添加剂例如分散剂和/或增稠剂。
用于乳胶衍生的预涂层中的典型的聚合物树脂包括聚合物组分诸如乙酸乙烯酯-乙烯(VAE)、苯乙烯-丁二烯橡胶(SBR)、聚氯乙烯(PVC)、聚酯、聚氨酯和聚烯烃,尤其是聚丙烯。可使用常规的热熔性粘合剂或其它非水性粘合剂例如乙烯乙酸乙烯酯(EVA)、聚烯烃和聚乙烯作为预涂层,其有时代替乳胶使用以提供比乳胶粘合剂更强的粘结。
在优选的实施方案中,所述预涂层包含阻燃添加剂诸如三水合铝(ATH)或氢氧化镁(Mg(OH)2)。优选为ATH。
在乳胶衍生的预涂层中,预涂层中阻燃添加剂的用量部分取决于粘合聚合物或存在的聚合物组分的性质和数量,以及预涂层的用量,并且可在至多600份每百份预涂层中聚合物树脂(phr)中变化。(预涂层中的聚合物组分与包含PTT的本文所公开的组合物的树脂组分分离并分开)。通常使用至多400phr,例如1至400phr的负载。优选使用100至400,更优选100至300份每百份的阻燃剂负载。
对于基于热熔性粘合剂的预涂层,预涂层中的阻燃添加剂诸如ATH的用量是基于粘合剂和填料诸如碳酸钙的量计的,并且可在至多约35重量%,例如从1至35重量%变化。优选使用1至25重量%的阻燃剂负载。更优选使用10-25%的阻燃剂。
一些毯包括除预涂层之外的第二背衬。所述第二背衬粘附到预涂层并且是毯结构的部分,所述毯结构与待铺毯的表面接触。在一些应用中,所述毯具有自粘着和自剥离的粘性第二背衬;在其它应用中,将粘固剂或胶水用于第二背衬上。与衍生自乙烯基聚合物例如PVC的第二背衬相比,衍生自聚烯烃的第二背衬通常需要在面纤维和预涂层中具有更高的阻燃剂负载。
已发现,预涂层中阻燃剂的量可基于毯中面纤维的重量,以及如果存在的话,第二背衬的基重和种类而有利地调整。“基重”是本领域的技术人员已知的术语,并且用于指每单位面积(以平方码计)的毯、第二背衬、或预涂层的重量(以盎司计)。因此,通常毯或预涂层的基重以盎司/平方码为单位报告。面纤维是指毯的纤维含量,包括对观察者可见的纤维。所述面纤维主要由纱线制成,并且这些纱线可以剪切、缠绕、剪切和缠绕或本领域的技术人员已知的任何数量的方式来修整。面纤维的重量还通常以例如盎司/平方纱线为单位报告。在毯通常称作阔幅毯的情况下,所述第二背衬可为厚乳胶。作为另外一种选择,在方块基毯的情况下,所述第二背衬可以是烯烃衍生或乙烯基衍生的。所述第二背衬可包含例如由玻璃纤维稀松布分离的多个层,并且所述多个层中的一个或多个可包含纤维。
对于很多应用,期望毯符合ASTM648E(辐射板测试)中评定的“1级”。然而已发现,仅增加毯纤维中的阻燃剂含量产生不一致的结果。此 外,仅在预涂层中使用较高含量的阻燃剂具有有限的效果,因为含量过高可不利地影响预涂层的粘附特性并导致簇绒基底从第二背衬中层离。
已令人惊讶地发现,当使用含ATH的预涂层制备毯并且在毯的面纤维中存在额外的阻燃剂时,具体地,当毯的面纤维由本文所公开的PTT基组合物制成时,与仅在纤维或仅在预涂层中包含阻燃添加剂的毯相比,观察到阻燃性改善。更具体地,在辐射板测试中此类毯的性能好于基于仅在面纤维中使用阻燃添加剂,或仅在预涂层中使用阻燃添加剂诸如ATH所预料的性能。在一些实施方案中,所述改善使得辐射板性能值大于仅以预涂层中的阻燃剂和仅以毯纤维中的阻燃剂获得的辐射板性能值的总和。这使得产生被评为1级的方块毯。
在优选的实施方案中,在28盎司/码2或更小,以及在一些实施方案中在24盎司/码2或更小的毯基重下,所述毯在纤维中包含2重量%或更少的阻燃剂。
实施例
成分
用于实施例的PTT为可得自E.I.du Pont de Nemours and Company(Wilmington,DE)的“半亮”聚合物。用于实施例的阻燃化合物如下表1中所陈述。
表1
测定在辐射板测试中的改善的方法是制备包含阻燃添加剂的膨体连续长丝(BCF)以及制备用于测试的包含所述BCF的毯样品。
配混
制备每种阻燃添加剂在PTT中的25%浓缩物。在三个独立的加料斗中放置25%浓缩物、PTT和着色颜料。使用旨在递送三个独立的加料斗的内容物的添加剂进料器,以在使用典型方法例如在美国专利7013628中描述的那些来熔融纺丝纤维期间,使PTT、阻燃添加剂和着色颜料以适当的重量百分比混合。
用作预涂层的乳胶粘合剂从BizMax Solutions Inc.获得。所述预涂层是基于VAE的并且视纤维的重量包含从0至300phr变化的ATH。以大约25盎司/码2的基重将预涂层施用到毯样品上。
第二背衬是得自LyondellBasell公司的挤出级热塑性聚烯烃TKP882DTPO融合物(merge),基于TPO的重量计,包含65重量%的碳酸钙作为填料。将各自大约40盎司/平方码,并且在其间具有2.1盎司/码2的玻璃纤维的两个挤出层施用在预涂覆的初级基底上。
辐射板测试
制备方块毯样品并根据ASTM648E使其进行辐射板测试。测定临界辐射光通量(CRF)并将不含阻燃添加剂的样品的结果捕集在下表2中。
表2
辐射板结果绘制在图1中。将在0.45和0.55watts/cm2下的基准线并入图中。前者是在辐射板测试中评为1级所预期的平均值。然而,后者是考虑到测试的变异性而实际使用的平均值,对于方块毯生产者而言其也提供舒适的余裕。回归线的斜率显示:在较低纤维面重量下,毯在辐射板测试中表现更好。增加预涂层中的ATH负载也改善了所述方块毯在辐射板测试中的性能。
方块毯的CRF结果示出于表3中,所述方块毯在纤维中包含各种阻燃添加剂OP950负载以及包含各种ATH负载的预涂层。
表3
图2示出毯面纤维中的OP950和毯预涂层中的ATH两者对毯在辐射板测试中的性能的影响。上表1和2中的数据示出了在预涂层中包括ATH以及在毯样品的面纤维中包括OP-950的有利效果。考虑比较实施例1,其中在纤维中不存在FR添加剂或者在预涂层中不存在ATH,CRF为0.38watts/cm2。在比较实施例6中发现,在预涂层中加入200phr的ATH,使CRF从0.38提高至0.48watts/cm2,增加了0.1CRF单位。参见实施例7,在面纤维中加入正好2%的OP950以使CRF提高至0.44watts/cm2,比比较实施例1中所观察的CRF增加0.06CRF单位。
如果OP950在面纤维中和ATH在预涂层中的效果是简单累加的,则包含两者的方块毯的预期CRF将为0.38watts/cm2+0.1watts/cm2+0.06watts/cm2或0.54watts/cm2。然而,出乎意料的是,在实施例13中发现所观察到的辐射光通量为0.63watts/cm2。
如在表4中可见,还可在辐射板测试中发现改善的性能,其中将阻燃剂例如MPP与MC以及ATH一起用于预涂层中。此外,当将ATH用于预涂层中时,MPP和MC的共混物(实施例23)、MPP和OP950的共混物(实施例24)、以及MC和OP950的共混物(实施例25)也极大地改善了毯样品的辐射板性能。每种共混组分的相对重量百分比也附带呈现于表中。图3示出各种阻燃添加剂及其CRF结果。
表4
Claims (22)
1.聚(对苯二甲酸丙二醇酯)基组合物,包含:(a)基于所述组合物总重量计,约75至约99.9重量%的树脂组分,其中基于所述树脂组分的重量计,所述树脂组分包含至少约70重量%的聚(对苯二甲酸丙二醇酯);以及(b)基于所述组合物总重量计,约0.1至约25重量%的添加剂包,其中基于所述组合物总重量计,所述添加剂包包含约0.1至约15重量%的氰尿酸三聚氰胺、焦磷酸三聚氰胺、二乙基次膦酸的锌盐、或它们的共混物。
2.根据权利要求1所述的聚(对苯二甲酸丙二醇酯)基组合物,其中所述氰尿酸三聚氰胺为非卤化的氰尿酸三聚氰胺。
3.根据权利要求1所述的聚(对苯二甲酸丙二醇酯)基组合物,其中所述氰尿酸三聚氰胺和焦磷酸三聚氰胺是颗粒状的并且具有小于约10微米的平均粒度。
4.根据权利要求1所述的聚(对苯二甲酸丙二醇酯)基组合物,其中基于组合物总重量计,所述添加剂包包含约0.5至约10重量%的氰尿酸三聚氰胺、焦磷酸三聚氰胺、二乙基次膦酸的锌盐、或它们的共混物。
5.根据权利要求1所述的聚(对苯二甲酸丙二醇酯)基组合物,其中基于组合物总重量计,所述添加剂包包含约1至约6重量%的氰尿酸三聚氰胺、焦磷酸三聚氰胺、二乙基次膦酸的锌盐、或它们的共混物。
6.根据权利要求1所述的聚(对苯二甲酸丙二醇酯)基组合物,其中所述聚(对苯二甲酸丙二醇酯)通过对苯二甲酸或酸等同物与1,3-丙二醇的缩聚反应制得。
7.根据权利要求6所述的聚(对苯二甲酸丙二醇酯)基组合物,其中所述1,3-丙烷为生物衍生的1,3-丙二醇。
8.根据权利要求1所述的聚(对苯二甲酸丙二醇酯)基组合物,其中所述聚(对苯二甲酸丙二醇酯)为聚(对苯二甲酸丙二醇酯)均聚物。
9.根据权利要求1所述的聚(对苯二甲酸丙二醇酯)基组合物,其中所述树脂组分包含第二聚合物。
10.根据权利要求9所述的聚(对苯二甲酸丙二醇酯)基组合物,其中所述第二聚合物选自:聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯和尼龙。
11.根据权利要求1所述的聚(对苯二甲酸丙二醇酯)基组合物,其中所述添加剂包包含TiO2。
12.制备权利要求1的聚(对苯二甲酸丙二醇酯)基组合物的方法,包括:(a)提供所述氰尿酸三聚氰胺、焦磷酸三聚氰胺、二乙基次膦酸的锌盐或它们的共混物以及所述聚(对苯二甲酸丙二醇酯);(b)将所述聚(对苯二甲酸丙二醇酯)和所述氰尿酸三聚氰胺、焦磷酸三聚氰胺、二乙基次膦酸的锌盐或它们的共混物混合以形成混合物;以及(c)在搅拌下将所述混合物加热并共混以形成所述组合物。
13.根据权利要求12所述的方法,其中在约180℃至约270℃的温度下进行步骤(c)。
14.由权利要求1的聚(对苯二甲酸丙二醇酯)基组合物制成的制品。
15.根据权利要求14所述的制品,所述制品为纤维的形式。
16.由权利要求15的纤维制成的毯。
17.包含面纤维和预涂层的毯,其中:所述面纤维由权利要求1的组合物制成,并且所述预涂层包含选自三水合铝和氢氧化镁的阻燃添加剂。
18.根据权利要求17所述的毯,其中所述预涂层是乳胶衍生的并且基于所述预涂层中的树脂组分的总重量计包含400phr或更少的量的所述阻燃剂。
19.根据权利要求18所述的毯,其中所述阻燃剂为ATH。
20.根据权利要求17所述的毯,其中所述预涂层包含热熔性粘合剂并且基于所述预涂层中的树脂组分的总重量计包含25重量%或更少的量的所述阻燃剂。
21.根据权利要求17所述的毯,其中所述预涂层是乳胶衍生的并且基于所述预涂层中的树脂组分的总重量计包含300phr或更少的量的所述阻燃剂三水合铝,并且其中在28盎司/码2或更小的毯基重下,所述毯在所述纤维中包含2重量%或更少的二乙基次膦酸的锌盐。
22.根据权利要求21所述的毯,其中所述毯表现出辐射板性能值,所述辐射板性能值大于仅以所述预涂层中的阻燃剂和仅以所述毯纤维中的阻燃剂获得的辐射板性能值的总和。
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2011
- 2011-05-16 WO PCT/US2011/036575 patent/WO2011159414A2/en active Application Filing
- 2011-05-16 AU AU2011265686A patent/AU2011265686B2/en not_active Ceased
- 2011-05-16 TR TR2018/09051T patent/TR201809051T4/tr unknown
- 2011-05-16 JP JP2013515345A patent/JP5855647B2/ja not_active Expired - Fee Related
- 2011-05-16 EP EP17190296.8A patent/EP3290468A1/en not_active Withdrawn
- 2011-05-16 MX MX2012014805A patent/MX2012014805A/es not_active Application Discontinuation
- 2011-05-16 BR BR112012031987A patent/BR112012031987A2/pt not_active Application Discontinuation
- 2011-05-16 CA CA2802672A patent/CA2802672C/en not_active Expired - Fee Related
- 2011-05-16 TW TW100117091A patent/TWI523993B/zh not_active IP Right Cessation
- 2011-05-16 KR KR1020137001144A patent/KR101857833B1/ko active IP Right Grant
- 2011-05-16 DK DK11796126.8T patent/DK2582756T3/en active
- 2011-05-16 CN CN201180038598.8A patent/CN103068920B/zh not_active Expired - Fee Related
- 2011-05-16 EP EP11796126.8A patent/EP2582756B1/en not_active Not-in-force
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CN1894319A (zh) * | 2003-12-17 | 2007-01-10 | 通用电气公司 | 阻燃性聚酯组合物 |
WO2009020944A1 (en) * | 2007-08-06 | 2009-02-12 | E.I. Du Pont De Nemours And Company | Flame retardant polytrimethylene terephthalate composition |
Also Published As
Publication number | Publication date |
---|---|
JP2013530283A (ja) | 2013-07-25 |
CA2802672C (en) | 2017-07-04 |
EP2582756B1 (en) | 2018-03-28 |
EP2582756A4 (en) | 2013-12-04 |
MX2012014805A (es) | 2013-02-07 |
AU2011265686B2 (en) | 2015-01-15 |
EP3290468A1 (en) | 2018-03-07 |
CN103068920B (zh) | 2016-08-03 |
AU2011265686A1 (en) | 2013-01-10 |
KR101857833B1 (ko) | 2018-05-14 |
KR20130100958A (ko) | 2013-09-12 |
DK2582756T3 (en) | 2018-06-18 |
WO2011159414A3 (en) | 2012-04-05 |
WO2011159414A2 (en) | 2011-12-22 |
TW201202505A (en) | 2012-01-16 |
JP5855647B2 (ja) | 2016-02-09 |
EP2582756A2 (en) | 2013-04-24 |
BR112012031987A2 (pt) | 2017-05-02 |
TR201809051T4 (tr) | 2018-07-23 |
CA2802672A1 (en) | 2011-12-22 |
TWI523993B (zh) | 2016-03-01 |
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