WO1992008758A1 - Silicone surface-modified ammonium polyphosphate - Google Patents

Silicone surface-modified ammonium polyphosphate Download PDF

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Publication number
WO1992008758A1
WO1992008758A1 PCT/US1991/007074 US9107074W WO9208758A1 WO 1992008758 A1 WO1992008758 A1 WO 1992008758A1 US 9107074 W US9107074 W US 9107074W WO 9208758 A1 WO9208758 A1 WO 9208758A1
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Prior art keywords
polymer
particles
organosiloxane
composition
terminated
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PCT/US1991/007074
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French (fr)
Inventor
Paritosh M. Chakrabarti
Kenneth J. Sienkowski
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Ppg Industries, Inc.
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Publication date
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Publication of WO1992008758A1 publication Critical patent/WO1992008758A1/en

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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K9/00Use of pretreated ingredients
    • C08K9/08Ingredients agglomerated by treatment with a binding agent

Definitions

  • Ammonium polyphosphate is an important ingredient for providing fire retardancy to many organic polymers.
  • APP can be used alone or it can be used with various synergists, depending upon the polymer system in which it is used.
  • APP can be used alone in poly(ester urethane) systems, whereas it is generally used with carbonific and/or spumific agents in polyolefin systems, epoxy systems, and poly(ether urethane) systems.
  • APP is useful as a fire retardant in many other polymer systems.
  • polyolefins for insulating electrically conducting wiring.
  • the polyolefin insulation is a good electrical insulator and, when used alone, is substantially waterproof.
  • the main disadvantage of polyolefin insulation is its flammability. Once ignited, the burning polyolefin produces copious amounts of smoke and drips burning liquid polyolefin which tends to spread the fire.
  • Polyolefin insulated wires and cables and bundles of these are therefore substantial firehazards. It is commonplace in buildings and ships to have bundles of insulated electrical wires and cables passing through openings in walls or bulkheads to expedite the delivery of electrical power from room to room. In time of fire these openings can be instrumental in spreading the fire and smoke from room to room.
  • Carbonifics are nonresinous materials which produce large volumes of both nonflammable gas and carbon in the presence of phosphoric acid.
  • Carbonific materials are generally carbohydrates or polyfunctional alcohols such as pentaerythritol.
  • Spumifics are materials which release large quantities of gas at elevated temperatures.
  • Spumifics are often resinous in nature and often act as binders in addition to forming gas.
  • Spumific materials are most often amides or amines such as urea, guanidine, or dicyandiamide, which liberate gaseous pyrolysis products.
  • APP is particularly useful because it has a high phosphorus content and because it yields phosphoric acid at temperatures below the decomposition temperatures of the carbonifics and spumifics and yet above the normal temperatures used for processing the intumescent composition.
  • ammonium polyphosphate suffers from the distinct disadvantage that it is water-soluble.
  • Electrical insulation containing APP is generally deficient in water resistance. Leaching of APP from the composition can lead to failure of the electrical insulating properties of the composition, and reduction of fire retardancy due to the loss of potential phosphoric acid necessary for the intumescent process.
  • one embodiment of the invention is particles of surface-modified ammonium polyphosphate comprising particulate ammonium polyphosphate surface-modified with organosiloxane polymer wherein the organosiloxane polymer constitutes from about 0.01 to about 5 percent by weight of the particles.
  • organosiloxane polymers which may be used in the present invention are many and widely varied. In general such polymers are characterized by the presence of one or more organosiloxane groups in the polymer. Usually the organosiloxane polymer comprises more than one such group.
  • the organosiloxane polymer may be a linear polymer, a branched polymer, a copolymer of two or more monomers, or a mixture of polymers. Copolymers may be random copolymers, block copolymers, and/or graft copolymers.
  • the terminal groups may also vary widely. Usually they are the same but they may be different.
  • the particles of surface-modified APP may be further processed to condense, addition polymerize, or otherwise polymerize the applied polymer to form longer chains, networks, and/or cyclic structures. In some cases such reactions take place during formulation of the particles of surface-modified APP with the organic polymer. Whether such polymerization reactions occur or not depends upon the nature of the functional groups, if any, present in the applied polymer and upon the conditions to which the applied polymer is exposed. For example, silanol-functional polymers can be further polymerized by heating at elevated temperatures.
  • Polymers having ethylenic unsaturation can be addition polymerized by exposure to ionizing radiation or actinic light or by heating in the presence of free radical initiator such as benzoyl peroxide [CAS 94-36-0] , diisopropyl peroxydicarbonate [CAS 105-64-6], or ⁇ , ⁇ '-azobisisobutyronitrile [CAS 78-67-1]. These reactions and the conditions under which they occur are well known in the art.
  • free radical initiator such as benzoyl peroxide [CAS 94-36-0] , diisopropyl peroxydicarbonate [CAS 105-64-6], or ⁇ , ⁇ '-azobisisobutyronitrile [CAS 78-67-1].
  • the molecular weight of the organosiloxane polymer which is" applied to the particulate APP is susceptible to extremely wide variation. Usually, but not necessarily, the number average molecular weight of the applied organosiloxane polymer is at least about 2000. The maximum number average molecular weight is limited only by the requirement that the polymer, either neat or dissolved in solvent, may be applied to the particulate APP as a liquid.
  • organosiloxane polymers suitable for use in the present invention include the following, where percentages are by weight: poly(dimeth lsiloxane), trimethylsiloxy terminated; poly(dimethylsiloxane), branched; poly(dimethylsiloxane), hydroxydimethylsiloxy terminated; poly(dimethylsiloxane), acetoxydimethylsiloxy terminated; poly(dimethylsiloxane), methyldiacetoxysiloxy terminated; poly(d_Lmethylsiloxane), chlorodimethylsiloxy terminated; poly(dimethylsiloxane), aminodimethylsiloxy terminated; poly(dimethylsiloxane), ethoxydimethylsiloxy terminated; poly(dimethylsiloxane), vinyldimethylsiloxy terminated; poly(dimethylsiloxane), methyldivinylsiloxy terminated; poly(di ⁇ _eth
  • the organosiloxane polymer constitutes from about 0.01 to about 5 percent by weight of the particles. Frequently the organosiloxane polymer constitutes from about 0.05 to about 3 percent by weight of the particles. From about 0.1 to about 1 percent by weight is preferred.
  • the particles of surface-modified APP of the invention may be prepared by admixing particulate APP with a solution of the organosiloxane polymer and then removing the solvent. Any inert solvent which will dissolve the organosiloxane polymer while not dissolving significant amounts of the APP can be used.
  • suitable inert solvents include chlorinated aliphatic hydrocarbons such as methylene chloride, chloroform, and the like, aromatic hydrocarbons such as toluene, xylene, and the like, and/or chlorinated aromatic hydrocarbons such as chlorobenzene, and the like.
  • the treated APP particles are separated from the bulk of the organosiloxane polymer solution by decantation, filtration, or centrifugation, and the residual solvent is then removed by evaporation (i. e., drying) at ambient or elevated temperatures.
  • the organosiloxane polymer solution may be applied to the particulate APP. Any of the well known methods of applying liquids to particlate materials may be used.
  • Examples include spraying or dipping.
  • the particlulate APP is mixed or agitated during the application.
  • Mechanical mixers, pneumatic mixers, and fluidized beds are useful for this purpose.
  • the residual solvent is removed by evaporation.
  • the relative amounts of particulate APP and dissolved organosiloxane polymer which are admixed may vary considerably and depend upon whether or not the treated APP particles are removed from the bulk of the organosiloxane polymer solution before evaporation of the solvent.
  • the particles of surface-modified APP of the invention may often be prepared by applying liquid neat organosiloxane polymer to particulate APP.
  • Any of the well known methods of applying neat liquids to particlate materials may be used. Examples include spraying or dripping. Usually the particlate materials are mixed or agitated during the application. Mechanical mixers, pneumatic mixers, and fluidized beds are useful for this purpose.
  • the temperature of the neat organosiloxane polymer during application is at least 0°C or the melting point of the organosiloxane polymer, whichever is higher.
  • the temperature of the neat organosiloxane polymer during application is not greater than about 300 ⁇ C or the decomposition temperature of the organosiloxane polymer, whichever is lower.
  • the relative amounts of neat organosiloxane polymer and particulate APP which are admixed may vary considerably, but usually the weight ratio of the organo ⁇ iloxane polymer to the particulate APP is in the range of from about 0.01:99.99 to about 5:95. Frequently the weight ratio is in the range of from about 0.05:99.95 to about 3:97. A weight ratio in the range of from about 0.1:99.9 to about 1:99 is preferred.
  • the organic polymer is usually flammable but in some cases it may be nonflammable. Ordinarily the organic polymer is thermoplastic.
  • the organic polymer may be a homopolymer, a copolymer, a terpolymer, an interpolymer, a graft polymer, or a mixture of polymers. Examples of polymers which may be used include polyolefins, polystyrene, polyesters, polyamides, polyurethanes (including poly(ester urethanes) and poly(ether urethanes)), and polycarbonates.
  • the preferred organic polymers are the polyolefins, including polyethylene (high density, medium density, low density, linear low density, or mixtures), polypropylene (atactic, isotactic, syndiotactic, stereoblock, or mixtures), copolymers of ethylene and propylene, copolymers of ethylene and vinyl acetate, and mixtures thereof, and poly(ester urethanes).
  • compositions of the invention are subject to wide variation.
  • weight ratio of the particles of surface-modified APP to the organic polymer is in the range of from about 10:100 to about 100:100.
  • weight ratio is in the range of from about 15:100 to about 85:100.
  • a weight ratio in the range of from about 20:100 to about 70:100 is preferred.
  • the composition also comprise ⁇ carbonific, spumific, or a mixture thereof.
  • the amounts of the carbonific, spumific, or mixture thereof which may be present in compositions of the invention are subject to wide variation.
  • the weight ratio of the carbonific, spumific, or mixture thereof to the particles of surface-modified APP is ordinarily in the range of from about 10:100 to about 100:100. Often the weight ratio is in the range of from about 15:100 to about 80:100. A weight ratio in the range of from about 25:100 to about 60:100 is preferred.
  • One or more other materials which increa ⁇ e fire retardancy may optionally also be present in the composition. Examples of such materials include organic fire retardant compound.
  • the organic fire retardant compound is halogen-containing organic fire retardant compound.
  • the chlorine-containing and bromine-containing organic fire retardant compounds are preferred.
  • organic fire retardant compounds which may be used in most cases include octabromodiphenyl oxide, decabromodiphenyl oxide, l,2-bi ⁇ (tribromophenoxy)ethane, N-methylhexabromodiphenylamine, poly[2,2-bis(bromomethyl)trimethylene carbonate], and any of the usual halogen-containing organic fire retardants.
  • compositions of the invention may optionally contain plasticizers, pigments, dyes, tints, antioxidants, visible light ⁇ tabilizers, ultraviolet light stabilizers, and the like.
  • compositions of the present invention have fire retardant characteristics and find many uses. They may be extruded into fibers, films, or other shapes, or molded, shaped, or formed into substantially any form. A preferred use, however, is as electrical insulation for wires and cables.
  • the invention is further described in conjunction with the following examples which are to be considered illustrative rather than limiting, and in which all parts are parts by weight and all percentages are percentages by weight unless otherwise specified.
  • a one percent organosiloxane polymer solution was prepared by adding 0.35 gram of organosiloxane polymer to 35 grams of methylene chloride. This solution was covered and stirred with a magnetic stirrer for 10 minutes. Next, 10 grams of APP particles was added to the organosiloxane polymer solution and the mixture was stirred for 15 minutes. Stirring was then terminated and the APP particles were allowed to settle. The excess organosiloxane polymer solution was pipetted off and discarded. The treated APP particles were then air-dried overnight in a hood to evaporate off the residual solvent. The dried powder was then ground to break up agglomerates and to obtain a freeflowing powder. This powder was stored in sealed test tubes.
  • the film was cut into three sections. These were stacked and placed between the polytetrafluoroethylene plates with 1.6 millimeter struts, and pressed once again in the laboratory press. This cutting, stacking, and pressing proces ⁇ was repeated until the films had a homogeneous appearance without visible air bubbles (if possible) in the film. In this manner 1.6 millimeter thick plaques were obtained for water immersion studies.
  • APP Leaching Test specimens measuring either 5.08 centimeters x 2.54 centimeters or 6.99 centimeters x 3.81 centimeter ⁇ were cut from the plaque ⁇ .
  • Samples were immersed in 237 milliliter wide mouth borosilicate jars filled with distilled-deionized water. The jars were sealed and placed in an 80°C oven for 14 days.
  • the samples were analyzed for phosphorus content by X-ray fluorescence (XRF) and by elemental analysis (EA).
  • XRF X-ray fluorescence
  • EA elemental analysis
  • the result of an X-ray fluorescence analysis is an indication of the phosphorus content of a thin surface region of the sample.
  • the result of an elemental analysis is an indication of the average phosphorus content throughout the bulk of the sample.

Abstract

The water leaching of ammonium polyphosphate from compositions comprising organic polymer and particles of ammonium polyphosphate is reduced if the ammonium polyphosphate is surface-modified with organosiloxane polymer. The organosiloxane polymer constitutes from about 0.01 to about 5 percent by weight of the surface-modified ammonium polyphosphate particles.

Description

SILICONE SURFACE-MODIFIED AMMONIUM POLYPHOSPHATE
Ammonium polyphosphate, often abbreviated "APP", is an important ingredient for providing fire retardancy to many organic polymers. APP can be used alone or it can be used with various synergists, depending upon the polymer system in which it is used. For example, APP can be used alone in poly(ester urethane) systems, whereas it is generally used with carbonific and/or spumific agents in polyolefin systems, epoxy systems, and poly(ether urethane) systems. These are only exemplary and APP is useful as a fire retardant in many other polymer systems.
The use of polyolefins for insulating electrically conducting wiring is known. Generally the polyolefin is extruded around the wire during manufacture. The polyolefin insulation is a good electrical insulator and, when used alone, is substantially waterproof. The main disadvantage of polyolefin insulation is its flammability. Once ignited, the burning polyolefin produces copious amounts of smoke and drips burning liquid polyolefin which tends to spread the fire. Polyolefin insulated wires and cables and bundles of these are therefore substantial firehazards. It is commonplace in buildings and ships to have bundles of insulated electrical wires and cables passing through openings in walls or bulkheads to expedite the delivery of electrical power from room to room. In time of fire these openings can be instrumental in spreading the fire and smoke from room to room.
Various fire retardants have been admixed with the polyolefin in order to provide fire retardancy to the composition. These have been only partially successful, however, because most fire retardants are not very compatible with polyolefins or because they are prohibitively expensive for commercial applications.
One approach that has been followed is the incorporation of materials which impart intumescence to the polyolefin-based insulation composition. Such intumescent compositions form adherent chars which swell up and impede further burning of the underlying composition.. One class of intumescent compositions used for electrical wiring insulation comprises polyolefin, ammonium polyphosphate, and at least one carbonific or spumific. Carbonifics are nonresinous materials which produce large volumes of both nonflammable gas and carbon in the presence of phosphoric acid. Carbonific materials are generally carbohydrates or polyfunctional alcohols such as pentaerythritol. Spumifics are materials which release large quantities of gas at elevated temperatures. Spumifics are often resinous in nature and often act as binders in addition to forming gas. Spumific materials are most often amides or amines such as urea, guanidine, or dicyandiamide, which liberate gaseous pyrolysis products.
APP is particularly useful because it has a high phosphorus content and because it yields phosphoric acid at temperatures below the decomposition temperatures of the carbonifics and spumifics and yet above the normal temperatures used for processing the intumescent composition.
Notwithstanding its advantages, ammonium polyphosphate suffers from the distinct disadvantage that it is water-soluble.
Electrical insulation containing APP is generally deficient in water resistance. Leaching of APP from the composition can lead to failure of the electrical insulating properties of the composition, and reduction of fire retardancy due to the loss of potential phosphoric acid necessary for the intumescent process.
Encapsulation of APP particles by various polymers has been tried in an effort to solve the problem, but this has resulted in only marginal improvement. The results have been largely unsuccessful. It has now been found that surface modification of APP particles with organosiloxane polymers results in markedly improved water resistance. Althought it is not desired to be bound by any theory, it is believed that the surface energies of polyolefins and APP are so different they are substantially incompatable. It is believed that a goodly proportion of the APP particles will not be wetted by polyolefin under melt or near-melt processing conditions, and that these will have a tendency to form interlinked channels throughout the bulk of the composition. This will allow water attack, resulting not only in partial leaching of the APP, but also will lead to the creation of water channels through the bulk of the composition. The net results are loss of fire retardancy and loss of electrically insulative character.
Accordingly, and irrespective of any theory, one embodiment of the invention is particles of surface-modified ammonium polyphosphate comprising particulate ammonium polyphosphate surface-modified with organosiloxane polymer wherein the organosiloxane polymer constitutes from about 0.01 to about 5 percent by weight of the particles.
The types of organosiloxane polymers which may be used in the present invention are many and widely varied. In general such polymers are characterized by the presence of one or more organosiloxane groups in the polymer. Usually the organosiloxane polymer comprises more than one such group. The organosiloxane polymer may be a linear polymer, a branched polymer, a copolymer of two or more monomers, or a mixture of polymers. Copolymers may be random copolymers, block copolymers, and/or graft copolymers. The terminal groups may also vary widely. Usually they are the same but they may be different.
After application of the organosiloxane polymer to the APP, the particles of surface-modified APP may be further processed to condense, addition polymerize, or otherwise polymerize the applied polymer to form longer chains, networks, and/or cyclic structures. In some cases such reactions take place during formulation of the particles of surface-modified APP with the organic polymer. Whether such polymerization reactions occur or not depends upon the nature of the functional groups, if any, present in the applied polymer and upon the conditions to which the applied polymer is exposed. For example, silanol-functional polymers can be further polymerized by heating at elevated temperatures. Polymers having ethylenic unsaturation can be addition polymerized by exposure to ionizing radiation or actinic light or by heating in the presence of free radical initiator such as benzoyl peroxide [CAS 94-36-0] , diisopropyl peroxydicarbonate [CAS 105-64-6], or α,α'-azobisisobutyronitrile [CAS 78-67-1]. These reactions and the conditions under which they occur are well known in the art.
The molecular weight of the organosiloxane polymer which is" applied to the particulate APP is susceptible to extremely wide variation. Usually, but not necessarily, the number average molecular weight of the applied organosiloxane polymer is at least about 2000. The maximum number average molecular weight is limited only by the requirement that the polymer, either neat or dissolved in solvent, may be applied to the particulate APP as a liquid.
Examples of organosiloxane polymers suitable for use in the present invention include the following, where percentages are by weight: poly(dimeth lsiloxane), trimethylsiloxy terminated; poly(dimethylsiloxane), branched; poly(dimethylsiloxane), hydroxydimethylsiloxy terminated; poly(dimethylsiloxane), acetoxydimethylsiloxy terminated; poly(dimethylsiloxane), methyldiacetoxysiloxy terminated; poly(d_Lmethylsiloxane), chlorodimethylsiloxy terminated; poly(dimethylsiloxane), aminodimethylsiloxy terminated; poly(dimethylsiloxane), ethoxydimethylsiloxy terminated; poly(dimethylsiloxane), vinyldimethylsiloxy terminated; poly(dimethylsiloxane), methyldivinylsiloxy terminated; poly(diι_ethylsiloxane), (vinyl)(phenyl)(methyl)siloxy terminated;
(99.6-99.7%) dimethylsiloxane and (0.3-0.4%.) (vinyl, methyl)siloxane random copolymer, vinyldimethylsiloxy terminated; poly(dimethylsiloxane), aminopropyldimethylεiloxy terminated; poly(dimethylsiloxane), aminobutyldimethylεiloxy terminated; poly(ethylene oxide, propylene oxide) poly(dimethylsiloxane) ABA block copolymer, hydroxy terminated; poly(dimethylsiloxane), carboxypropyldimethylsiloxy terminated; poly(dimethylsiloxane), chloromethyldimethylsiloxy terminated; poly(dimethylsiloxane), methacryloxypropyldimethylsiloxy terminated; (80-99%) dimethylsiloxane and (1-20%) (vinyl, methyl)siloxane random copolymer, trimethylsiloxy terminated;
(80-85%) dimethylsiloxane and (15-20%) (acryloxypropyl, methyl)siloxane random copolymer, trimethylsiloxy terminated; (95-97%) dimethylsiloxane and (3-5%) (aminopropyl, methyl)siloxane random copolymer, trimethylsiloxy terminated; (90-95%) dimethylsiloxane and (5-10%) (chloromethylphenethyl, methyl)siloxane random copolymer, trimethylsiloxy terminated; (78-86%) dimethylsiloxane and (14-22%) (chloropropyl, methyl)siloxane random copolymer, trimethylsiloxy terminated; (84-86%) dimethylsiloxane and (14-16%) (chloropropyl, methyl)εiloxane random copolymer, vinyldimethylsiloxy terminated; (65-70%) dimethylsiloxane and (30-35%) (hexenyl, methyl)siloxane random copolymer, trimethylsiloxy terminated; (80-90%) dimethylsiloxane and (10-20%) (hydroxyalkylene oxide, methyl)siloxane random copolymer, trimethylsiloxy terminated; (84-86%) dimethylsiloxane and (14-16%) (iodopropyl, methyl)siloxane random copolymer, vinyldimethylsiloxy terminated; (97-98%) dimethylsiloxane and (2-3%) (methacryloxypropyl, methyl)siloxane random copolymer, trimethylsiloxy terminated; (65-70%) dimethylsiloxane and (30-35%) (octyloxy, methyl)siloxane random copolymer, trimethylsiloxy terminated; T-εtructure poly(dimethylsiloxane), carboxypropyldimethylsiloxy terminated; poly[(methyl, hydro)siloxane] , trimethylsiloxy terminated; (45-99.5%) dimethylsiloxane and (0.5-55%) (methyl, hydro)siloxane random copolymer, trimethylsiloxy terminated; (40-60%) (methyl, hydro)siloxane and (40-60%) (cyanopropyl, methyl)εiloxane random copolymer, trimethylsiloxy terminated; (25-60%) (methyl, hydro)siloxane and (40-75%) (octyl, methy1)siloxane random copolymer, trimethylsiloxy terminated; (45-50%) (methyl, hydro)siloxane and (50-55%) (phenyl, methyl)siloxane random copolymer, dimethyl(hydro)siloxy terminated; poly[(phenyl, dimethylεiloxy)εiloxane] , dimethyl(hydro)εiloxy terminated; ρoly[(hexyl, methyl)siloxane] , trimethylsiloxy terminated; poly[(octyl, methyl)siloxane] , trimethylsiloxy terminated; (56-64%) dimethylsiloxane, (35-40%) (octyl, methyl)siloxane, and
(3-4%) (vinyl, methyl)siloxane random terpolymer, trimethylsiloxy terminated; poly[(octadecyl, methyl)siloxane] , trimethylsiloxy terminated; (95-98%) (decyl, methyl)siloxane and (2-5%) (aryloxymethyl, methyl)siloxane random copolymer, trimethylsiloxy terminated; (48-52%) (hexyl, methyl)siloxanε and (48-52%) (phenethyl, methyl)siloxane random copolymer, trimethylsiloxy terminated; ρoly[(tetradecyl, methyl)siloxane] , trimethylsiloxy terminated; poly[(hexadecyl, methyl)siloxane] , trimethylεiloxy terminated; poly[(phenethyl, methyl)εiloxane] , vinyldimethylsiloxy terminated; poly[(phenyl, methyl)siloxane] , trimethylsiloxy terminated; (79-96%) dimethylεiloxane and (4-21%) diphenylsiloxane random copolymer, trimethylsiloxy terminated; (48-92%) dimethylsiloxane and (8-52%) (phenyl, methyl)siloxane random copolymer, trimethylεiloxy terminated; (45-55%) (phenyl, methyl)siloxane and (45-55%) diphenylsiloxane random copolymer, trimethylsiloxy terminated; (94-96%) dimethylsiloxane and (4-6%) (tolyl, methyl)εiloxane random copolymer, trimethylsiloxy terminated; poly(diphenylεiloxane), hydroxydimethylsiloxy terminated; (85-97%) dimethylsiloxane and (3-15%) diphenylsiloxane random copolymer, hydroxydimethylsiloxy terminated; (75-98%) dimethylsiloxane and (2-25%) diphenylsiloxane random copolymer, vinyldimethylεiloxy terminated;
(85-89%) dimethylεiloxane, (4-5%) diphenylεiloxane, and (7-10%)
(aminopropyl, methyl)siloxane random terpolymer, trimethylsiloxy terminated; (8-10%) (chloromethylphenethyl, methyl)siloxane, (8-10%) (phenyl, methyl)εiloxane, and (74-80%) diphenylεiloxane random terpolymer, trimethylεiloxy terminated; tetramethyldiεiloxane and ethylene copolymer, vinyldimethylεiloxy terminated. The preferred organosiloxane polymers are poly(dimethylsiloxane), trimethylsiloxy terminated and poly(dimethylsiloxane), hydroxydimethylsiloxy terminated.
The organosiloxane polymer constitutes from about 0.01 to about 5 percent by weight of the particles. Frequently the organosiloxane polymer constitutes from about 0.05 to about 3 percent by weight of the particles. From about 0.1 to about 1 percent by weight is preferred. The particles of surface-modified APP of the invention may be prepared by admixing particulate APP with a solution of the organosiloxane polymer and then removing the solvent. Any inert solvent which will dissolve the organosiloxane polymer while not dissolving significant amounts of the APP can be used. Examples of suitable inert solvents include chlorinated aliphatic hydrocarbons such as methylene chloride, chloroform, and the like, aromatic hydrocarbons such as toluene, xylene, and the like, and/or chlorinated aromatic hydrocarbons such as chlorobenzene, and the like. In most cases the treated APP particles are separated from the bulk of the organosiloxane polymer solution by decantation, filtration, or centrifugation, and the residual solvent is then removed by evaporation (i. e., drying) at ambient or elevated temperatures. Alternatively the organosiloxane polymer solution may be applied to the particulate APP. Any of the well known methods of applying liquids to particlate materials may be used. Examples include spraying or dipping. Usually the particlulate APP is mixed or agitated during the application. Mechanical mixers, pneumatic mixers, and fluidized beds are useful for this purpose. Following application the residual solvent is removed by evaporation. The relative amounts of particulate APP and dissolved organosiloxane polymer which are admixed may vary considerably and depend upon whether or not the treated APP particles are removed from the bulk of the organosiloxane polymer solution before evaporation of the solvent.
The particles of surface-modified APP of the invention may often be prepared by applying liquid neat organosiloxane polymer to particulate APP. Any of the well known methods of applying neat liquids to particlate materials may be used. Examples include spraying or dripping. Usually the particlate materials are mixed or agitated during the application. Mechanical mixers, pneumatic mixers, and fluidized beds are useful for this purpose. The temperature of the neat organosiloxane polymer during application is at least 0°C or the melting point of the organosiloxane polymer, whichever is higher. The temperature of the neat organosiloxane polymer during application is not greater than about 300βC or the decomposition temperature of the organosiloxane polymer, whichever is lower. The relative amounts of neat organosiloxane polymer and particulate APP which are admixed may vary considerably, but usually the weight ratio of the organoεiloxane polymer to the particulate APP is in the range of from about 0.01:99.99 to about 5:95. Frequently the weight ratio is in the range of from about 0.05:99.95 to about 3:97. A weight ratio in the range of from about 0.1:99.9 to about 1:99 is preferred.
Another embodiment of the invention is a composition comprising organic polymer and particles of surface-modified ammonium polyphosphate, the particles comprising particulate ammonium polyphosphate surface-modified with organoεiloxane polymer wherein the organoεiloxane polymer conεtitutes from about 0.01 to about 5 percent by weight of the particles, which particles of εurface-modified APP have been earlier described.
The organic polymer is usually flammable but in some cases it may be nonflammable. Ordinarily the organic polymer is thermoplastic. The organic polymer may be a homopolymer, a copolymer, a terpolymer, an interpolymer, a graft polymer, or a mixture of polymers. Examples of polymers which may be used include polyolefins, polystyrene, polyesters, polyamides, polyurethanes (including poly(ester urethanes) and poly(ether urethanes)), and polycarbonates. The preferred organic polymers are the polyolefins, including polyethylene (high density, medium density, low density, linear low density, or mixtures), polypropylene (atactic, isotactic, syndiotactic, stereoblock, or mixtures), copolymers of ethylene and propylene, copolymers of ethylene and vinyl acetate, and mixtures thereof, and poly(ester urethanes).
The amounts of surface-modified APP which are present in compositions of the invention are subject to wide variation. Ordinarily the weight ratio of the particles of surface-modified APP to the organic polymer is in the range of from about 10:100 to about 100:100. Often the weight ratio is in the range of from about 15:100 to about 85:100. A weight ratio in the range of from about 20:100 to about 70:100 is preferred.
In many cases the composition also compriseε carbonific, spumific, or a mixture thereof. The amounts of the carbonific, spumific, or mixture thereof which may be present in compositions of the invention are subject to wide variation. When used, the weight ratio of the carbonific, spumific, or mixture thereof to the particles of surface-modified APP is ordinarily in the range of from about 10:100 to about 100:100. Often the weight ratio is in the range of from about 15:100 to about 80:100. A weight ratio in the range of from about 25:100 to about 60:100 is preferred. One or more other materials which increaεe fire retardancy may optionally also be present in the composition. Examples of such materials include organic fire retardant compound. In most, but not all cases, the organic fire retardant compound is halogen-containing organic fire retardant compound. Of these, the chlorine-containing and bromine-containing organic fire retardant compounds are preferred. Examples of organic fire retardant compounds which may be used in most cases include octabromodiphenyl oxide, decabromodiphenyl oxide, l,2-biε(tribromophenoxy)ethane, N-methylhexabromodiphenylamine, poly[2,2-bis(bromomethyl)trimethylene carbonate], and any of the usual halogen-containing organic fire retardants.
One or more inorganic materials which will increase fire retardancy may optionally be present in the composition. Examples of such materials include zinc oxide, zinc borate, and ferric oxide. The compositions of the invention may optionally contain plasticizers, pigments, dyes, tints, antioxidants, visible light εtabilizers, ultraviolet light stabilizers, and the like.
The listing of optional ingredients discussed above is by - li ¬
no means exhauεtive. Theεe and other ingredientε may be employed in their customary amounts for their customary purposes so long as they are not antagoniεtic to flame retardant performance and good polymer formulating practice. The compositions of the present invention have fire retardant characteristics and find many uses. They may be extruded into fibers, films, or other shapes, or molded, shaped, or formed into substantially any form. A preferred use, however, is as electrical insulation for wires and cables. The invention is further described in conjunction with the following examples which are to be considered illustrative rather than limiting, and in which all parts are parts by weight and all percentages are percentages by weight unless otherwise specified.
EXAMPLES Surface Modification of APP Particles The following procedure was used to treat the APP particles. A one percent organosiloxane polymer solution was prepared by adding 0.35 gram of organosiloxane polymer to 35 grams of methylene chloride. This solution was covered and stirred with a magnetic stirrer for 10 minutes. Next, 10 grams of APP particles was added to the organosiloxane polymer solution and the mixture was stirred for 15 minutes. Stirring was then terminated and the APP particles were allowed to settle. The excess organosiloxane polymer solution was pipetted off and discarded. The treated APP particles were then air-dried overnight in a hood to evaporate off the residual solvent. The dried powder was then ground to break up agglomerates and to obtain a freeflowing powder. This powder was stored in sealed test tubes.
Dispersion of Surface-Modified APP in Polyethylene Thirty-five grams of Petrothene NA 117 polyethylene (US Industrial Chemicals) was added to the mixing chamber of a Brabender Plasti-corder torque rheometer at approximately 135°C until the polyethylene was completely melted. Next, 5.25 grams of surface-modified APP was carefully added into the mixing chamber to provide a loading level of 15 parts of surface-modified APP per hundred parts of polyethylene resin, by weight (phr). The materials were mixed together for 5 minutes at approximately 100 revolutions per minute. The molten mixture was then placed between polytetrafluoroethylene coated plates and pressed in a laboratory press at 350βC for several minutes until the mixture was pressed out flat. After cooling, the film was cut into three sections. These were stacked and placed between the polytetrafluoroethylene plates with 1.6 millimeter struts, and pressed once again in the laboratory press. This cutting, stacking, and pressing procesε was repeated until the films had a homogeneous appearance without visible air bubbles (if possible) in the film. In this manner 1.6 millimeter thick plaques were obtained for water immersion studies.
Determination of APP Leaching Test specimens measuring either 5.08 centimeters x 2.54 centimeters or 6.99 centimeters x 3.81 centimeterε were cut from the plaqueε. Samples were immersed in 237 milliliter wide mouth borosilicate jars filled with distilled-deionized water. The jars were sealed and placed in an 80°C oven for 14 days. The samples were analyzed for phosphorus content by X-ray fluorescence (XRF) and by elemental analysis (EA). The result of an X-ray fluorescence analysis is an indication of the phosphorus content of a thin surface region of the sample. The result of an elemental analysis is an indication of the average phosphorus content throughout the bulk of the sample. The identities of the organosiloxane polymerε employed are shown in Table 1 and the results are shown in Table 2. "MW" is an abbreviation for approximate number average molecular weight unless otherwise specified. Table 1 Organosiloxane Polymer Abbreviation Identity Silicone-1 Poly(dimethylsiloxane), trimethylsiloxy terminated; MW=110,000 Silicone-2 Poly(dimethylsiloxane), trimethylsiloxy terminated; MW=14,000
2
Figure imgf000015_0001
A comparison of the Bulk P by Elemental Analysis for the polymer encapsulated APP and the untreated APP shows that encapsulation is not very effective in reducing the water leaching of APP. Similar comparisons of APP surface-modified with the organoεiloxane polymers having at least one terminal hydrophobe containing at least about 12 carbon atoms with the untreated control shows that the surface-modification provided by the organosiloxane polymers was effective in reducing the water leaching of APP. The data also show that APP surface-modified with the organosiloxane polymers having at least one terminal hydrophobe containing at least about 12 carbon atoms tended to concentrate away from the surface of the samples. The reason for this iε not known, but the effect is a distinct advantage since less APP is exposed at the surface for water extraction.
Although the present invention has been described with reference to specific details of certain embodiments thereof, it is not intended that such details should be regarded as limitations upon the scope of the invention except insofar as they are included in the accompanying claims.

Claims

CLAIMS :
1. Particles of εurface-modified ammonium polyphosphate compriεing particulate ammonium polyphosphate surface-modified with organosiloxane polymer wherein said organosiloxane polymer constitutes from about 0.01 to about 5 percent by weight of said particles.
2. The particles of claim 1 wherein said organosiloxane polymer has a number average molecular weight of at least about 2000.
3. The particles of claim 1 wherein said organosiloxane iε a linear polymer.
4. The particleε of claim 1 wherein said organosiloxane is a branched polymer.
5. The particles of claim 1 wherein said organosiloxane is a copolymer of two or more monomers.
6. The particles of claim 1 wherein said organosiloxane polymer constitutes from about 0.05 to about 3 percent by weight of said particles.
7. The particles of claim 1 wherein said organosiloxane polymer constitutes from about 0.01 to about 1 percent by weight of said particles.
8. The particles of claim 1 wherein said organosiloxane polymer is poly(dimethylsiloxane), trimethylεiloxy terminated.
9. The particles of claim 1 wherein said organosiloxane polymer is poly(dimethylsiloxane), hydroxydimethylsiloxy terminated.
10. A composition comprising organic polymer and particles of surface-modified ammonium polyphosphate, said particles comprising particulate ammonium polyphosphate surface-modified with organosiloxane polymer wherein said organosiloxane polymer constitutes from about 0.01 to about 5 percent by weight of said particles.
11. The composition of claim 10 wherein said organosiloxane poisoner has a number average molecular weight of at least about 2000.
12. The composition of claim 10 wherein said organosiloxane is a linear polymer.
13. The composition of claim 10 wherein said organosiloxane is a branched polymer.
14. The composition of claim 10 wherein said organosiloxane is a copolymer of two or more monomers.
15. The composition of claim 10 wherein said organosiloxane polymer constitutes from about 0.05 to about 3 percent by weight of said particles.
16. The composition of claim 10 wherein said organosiloxane polymer constitutes from about 0.01 to about 1 percent by weight of said particles.
17. The composition of claim 10 wherein said organosiloxane polymer is poly(dimethylsiloxane), trimethylsiloxy terminated.
18. The composition of claim 10 wherein said organosiloxane polymer is poly(dimethylsiloxane), hydroxydimethylsiloxy terminated.
19. The composition of claim 10 wherein said polymer iε a polyolefin.
20. The composition of claim 10 wherein said polymer is polyethylene.
21. The composition of claim 10 wherein said polymer is polypropylene.
22. The composition of claim 10 wherein said polymer is copolymer of ethylene and propylene.
23. The composition of claim 10 wherein said polymer is polyurethane.
24. The composition of claim 10 wherein said polymer is poly(ester urethane).
25. The composition of claim 10 wherein the weight ratio of said particles of surface-modified APP to said organic polymer is in the range of from about 10:100 to about 100:100.
26. The composition of claim 10 wherein the weight ratio of said particles of surface-modified APP to said organic polymer is in the range of from about 15:100 to about 85:100.
27. The composition of claim 10 wherein the weight ratio of said particles of εurface-modified APP to εaid organic polymer is in the range of from about 20:100 to about 70:100.
PCT/US1991/007074 1990-11-08 1991-09-26 Silicone surface-modified ammonium polyphosphate WO1992008758A1 (en)

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EP0609035A1 (en) * 1993-01-27 1994-08-03 General Electric Company Organohydrogen polysiloxane coated phosphites
EP0943945A2 (en) * 1998-03-18 1999-09-22 Alcatel Flame resistant optical cable
US6291068B1 (en) 1997-06-26 2001-09-18 Chisso Corporation Thermoplastic resin-coated ammonium polyphosphate and process for the preparation thereof
CN102432920A (en) * 2011-08-17 2012-05-02 中科院广州化学有限公司 High-temperature-resistant nuclear-shell structure type flame retardant, and preparation method and application thereof
US8932497B2 (en) 2008-03-13 2015-01-13 Laxmi C. Gupta Fire retardant coatings and bodies, and methods of use
CN104479172A (en) * 2014-12-05 2015-04-01 黑龙江省润特科技有限公司 Preparation method of ammonium polyphosphate wrapped with fluorine-containing silicone oil on surface
CN105755802A (en) * 2016-02-25 2016-07-13 义乌市瑞宝智能科技有限公司 Organosilicone boric acid ester modified ammonium polyphosphate and preparing method and application of organosilicone boric acid ester modified ammonium polyphosphate

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CN104479172A (en) * 2014-12-05 2015-04-01 黑龙江省润特科技有限公司 Preparation method of ammonium polyphosphate wrapped with fluorine-containing silicone oil on surface
CN105755802A (en) * 2016-02-25 2016-07-13 义乌市瑞宝智能科技有限公司 Organosilicone boric acid ester modified ammonium polyphosphate and preparing method and application of organosilicone boric acid ester modified ammonium polyphosphate

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