JP2017179194A - Flame retardant composition - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a flame retardant composition having no generation of halogen-based gas or formaldehyde, exhibiting high flame retardancy and hardly generating sliminess or the like when applied to a fiber material.SOLUTION: There is provided a flame retardant composition containing a resin emulsion, aluminum phosphite, a surfactant having a nonylphenyl group and a melamine compound with the aluminum phosphite of 50 to 250 pts.wt. and the surfactant having the nonylphenyl group of 1 to 10 pts.wt. based on 100 pts.wt. of an acrylic resin emulsion.SELECTED DRAWING: None

Description

  The present invention relates to a flame retardant composition that does not generate halogen-based gas or formaldehyde, exhibits high flame retardancy, and is less susceptible to slime when applied to a fiber material.

Conventionally, various flame retardant additives have been used for the purpose of imparting flame retardancy to resins, elastomers and coating agents. For example, since halogen-containing compounds have high flame retardancy, they have been used alone or in combination with antimony compounds such as antimony oxide. On the other hand, flame retardant compositions in which these are blended in resins and emulsions are likely to generate halogen-based gases and carbon monoxide in the event of a fire, and are thus being avoided.
In addition, when metal hydroxide is used, there is no such problem, but in order to develop flame retardancy, it is necessary to add a large amount. Therefore, the original processability and mechanical strength of the compound are impaired. There is a problem such as.

Therefore, various phosphorus compounds have attracted attention as potential options and are actually widely used. Above all, ammonium polyphosphate is superior in flame retardancy, is safer than other phosphorus compounds, and is not easy to bleed out. It has been added to.

On the other hand, when the sheet fabric is placed under hot and humid conditions, or when water or hot water is spilled on the sheet fabric, ammonium polyphosphate is soluble in water and may easily elute on the surface, resulting in spots and slime. .
In addition, when manufacturing interior materials, ammonium polyphosphate is coated on the back of the textile fiber together with a binder component such as an acrylic resin and bonded to a urethane sheet base material. When ammonium polyphosphate is eluted on the surface There are cases in which the appearance is poor due to slippage of the woven fiber and the sheet base material due to slimming, and the occurrence of spots (wrinkles) after drying.

Patent Document 1 discloses an ammonium polyphosphate-containing substance coated with a thermoplastic resin. However, only a decrease in flame retardancy is evaluated as an effect of elution, and appearance defects that cause problems even with slight elution are disclosed. Has not been fully studied. Moreover, the storage stability in an aqueous solvent tends to be reduced by being coated with a thermoplastic resin.
Patent Document 2 discloses a resin composition using a phosphite-based flame retardant, and an acrylic resin suitable for a fiber processing resin binder, although it does not cause slimming because it does not use ammonium polyphosphate. Since it is inferior in dispersibility in emulsion and styrene-butadiene copolymer resin emulsion, it was not suitable for fiber processing.
JP 2001-262466 A Japanese Patent Application No. 2011-225723

An object of the present invention is to provide a flame retardant composition that does not generate a halogen-based gas or formaldehyde, exhibits high flame retardancy, and is less likely to cause slime when applied to a fiber material.

As a result of intensive studies by the present inventors, it has been found that by using a surfactant having a nonylphenyl group, a phosphorous acid flame retardant can be stably dispersed in a resin emulsion. It came to complete.
The present invention is a flame retardant composition comprising a resin emulsion, aluminum phosphite, and a surfactant having a nonylphenyl group.

  The flame retardant composition according to the present invention does not generate a halogen-based gas or formaldehyde, and does not easily cause slimming even when applied to a fiber material. Therefore, it is suitable for the use which gives a flame retardance to the fiber material used for the floor for vehicles, a mat, etc.

Although the present invention provides a flame retardant composition, the flame retardancy in the present invention means a function of suppressing, for example, the amount of combustion and the burning rate by resistance to flame, and it is not necessarily a specific standard. It does not mean that it conforms to or does not burn at all.

Resin emulsion The flame retardant composition of the present invention contains a resin emulsion as a binder component. Known resin emulsions can be used, but acrylic resin emulsions or styrene-butadiene copolymer resin emulsions are preferred from the viewpoints of flame retardancy, water resistance as a binder, prevention of blocking, and the like.
Further, when processed into a fiber product, the glass transition temperature (Tg) is more preferably 0 ° C. or higher so that a hard texture can be obtained.

Aluminum phosphite Aluminum phosphite is used to impart flame retardancy to the composition of the present invention. The production method is obtained, for example, by reacting ammonium dihydrogen phosphite and hydrous aluminum hydroxide, and is disclosed in detail in Japanese Patent No. 2899916. In addition, since it is inferior in the dispersibility to the said resin emulsion independently, it is necessary to use the surfactant which has the nonylphenyl group mentioned later as a dispersing agent.

The compounding amount of aluminum phosphite is preferably 50 to 250 parts by weight with respect to 100 parts by weight of the resin emulsion based on the solid content. By setting it as 50 weight part or more, a flame retardance improves notably, By making it 250 weight part or less, storage stability can be maintained, and the powder fall-off at the time of processing into a textiles can be suppressed.

Surfactant having nonylphenyl group In the flame retardant composition of the present invention, the surfactant having nonylphenyl group serves as a dispersant for stably dispersing aluminum phosphite in the resin emulsion. Examples of the surfactant having a nonylphenyl group include polyoxyalkylene nonylphenyl ether. Even if an anionic surfactant or a nonionic surfactant having no nonylphenyl group is used, aluminum phosphite cannot be stably dispersed in the resin emulsion.

The amount of the surfactant having a nonylphenyl group is preferably 1 to 10 parts by weight with respect to 100 parts by weight of the resin emulsion based on the solid content. When the amount is 1 part by weight or more, the dispersibility of aluminum phosphite is remarkably improved, and when the amount is 10 parts by weight or less, the hard texture of the fiber product can be maintained.

  By adding a viscosity modifier in addition to the surfactant having the nonylphenyl group, the storage stability of the dispersion and the miscibility with the resin emulsion can be further enhanced. Examples of the viscosity modifier include water-soluble polymers such as polyvinyl alcohol, hydroxyethyl cellulose, and xanthan gum, and inorganic compounds such as bentonite.

  A flame retardant compound other than aluminum phosphite may be added to the flame retardant composition of the present invention. Specific examples include melamine compounds such as melamine cyanurate. In addition, pigments, dyes, plasticizers, anti-aging agents, ultraviolet absorbers, preservatives, pH adjusters, and the like can be used as long as the effects of the present invention are not impaired.

  Hereinafter, the flame retardant composition and the production method thereof according to the present application will be specifically described with reference to Examples and Comparative Examples.

Example 1
Based on the solid content, acrylic resin emulsion ANX-150 (manufactured by Aika Industry, Tg 40 ° C., trade name) 100 parts by weight, Neugen EA-160 (Daiichi Kogyo Seiyaku, trade name) which is a surfactant having a nonylphenyl group The flame retardant composition of Example 1 was obtained by mixing 5 parts by weight, 150 parts by weight of aluminum phosphite, 25 parts by weight of melamine cyanurate, and Kelzan ASX which is xanthan gum as a thickener.

Example 2
In Example 1, the flame retardant composition of Example 2 was obtained in the same manner as in Example 1 except that the amount of Neugen EA-160 was 2 parts by weight and no melamine cyanurate was added.

Comparative Examples 1-3
In Example 1, it replaced with aluminum phosphite, and it carried out similarly to Example 1 except having mix | blended primary aluminum phosphate, secondary aluminum phosphate, and tertiary aluminum phosphate, respectively, and each of Comparative Examples 1-3 A flame retardant composition was obtained.

Comparative Example 4
In Example 1, it carried out similarly to Example 1 except not having mix | blended Neugen EA-160, and the flame-retardant composition of the comparative example 4 was obtained.

Comparative Examples 5-7
In Example 1, instead of Neugen EA-160, surfactants having no nonylphenyl group, sodium lauryl sulfate, sodium dodecylbenzenesulfonate, and emulgen 104P, polyoxyethylene lauryl ether (trade name, manufactured by Kao Corporation) ) Was carried out in the same manner as in Example 1 to obtain flame retardant compositions of Comparative Examples 5 to 7.

Storage Stability Test Each flame retardant composition was placed in a glass bottle and stored in a 40 ° C. atmosphere for 1 month, and then the viscosity was measured. The viscosity was evaluated as follows in comparison with the viscosity before storage.
○: Less than 50% thickening from initial viscosity x: 50% or more thickening from initial viscosity

Each flame-retardant composition the flame-retardant polyester nonwoven fabric (basis weight ^{250g / m 2) 80g / m} 2 was applied as a solid, and dried 10 minutes at 140 ° C. atmosphere. The sample was cut into 350 mm × 200 mm and left in a 20 ° C., 65% RH atmosphere for 24 hours as a sample.
In accordance with FMVSS-302, which is a flame retardant standard for the automotive interior field, the prepared sample was subjected to a combustion test by the horizontal method. The test was performed at four points, and the average burning rate (mm / min) and standard deviation (σ) were determined to be acceptable if the burning rate + 4σ = 100 or less.

  As the evaluation result of Table 1, each flame-retardant composition of an Example was favorable in both flame retardance and storage property. On the other hand, in Comparative Examples 1 to 3 not containing aluminum phosphite, the flame retardancy was not sufficient, and in Comparative Examples 4 to 7 not containing a surfactant having a nonylphenyl group, the storage stability was not sufficient. .

Claims (3)

A flame retardant composition comprising a resin emulsion, aluminum phosphite, and a surfactant having a nonylphenyl group. 2. A solid emulsion based on 100 parts by weight of a resin emulsion, containing 50 to 250 parts by weight of aluminum phosphite and 1 to 10 parts by weight of a surfactant having a nonylphenyl group. The flame retardant composition as described. Furthermore, a melamine compound is contained, The flame-retardant composition of Claim 1 or 2 characterized by the above-mentioned.