WO2020234173A1 - A flame-retardant composition - Google Patents

A flame-retardant composition Download PDF

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Publication number
WO2020234173A1
WO2020234173A1 PCT/EP2020/063662 EP2020063662W WO2020234173A1 WO 2020234173 A1 WO2020234173 A1 WO 2020234173A1 EP 2020063662 W EP2020063662 W EP 2020063662W WO 2020234173 A1 WO2020234173 A1 WO 2020234173A1
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WIPO (PCT)
Prior art keywords
flame
weight
retardant composition
retardant
range
Prior art date
Application number
PCT/EP2020/063662
Other languages
French (fr)
Inventor
Joao COSTA
Eric NOON
Gerard Finnegan
Mohammad HUDA
Original Assignee
Basf Se
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Publication date
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Publication of WO2020234173A1 publication Critical patent/WO2020234173A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/088—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/34—Heterocyclic compounds having nitrogen in the ring
    • C08K5/3467—Heterocyclic compounds having nitrogen in the ring having more than two nitrogen atoms in the ring
    • C08K5/3477—Six-membered rings
    • C08K5/3492—Triazines
    • C08K5/34926—Triazines also containing heterocyclic groups other than triazine groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/34—Heterocyclic compounds having nitrogen in the ring
    • C08K5/3467—Heterocyclic compounds having nitrogen in the ring having more than two nitrogen atoms in the ring
    • C08K5/3477—Six-membered rings
    • C08K5/3492—Triazines
    • C08K5/34928—Salts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/303—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups H01B3/38 or H01B3/302
    • H01B3/305—Polyamides or polyesteramides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/048—Natural or synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2553/00—Packaging equipment or accessories not otherwise provided for
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
    • D06M2200/30—Flame or heat resistance, fire retardancy properties
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/067—Flame resistant, fire resistant

Definitions

  • the presently claimed invention is directed to a flame-retardant composition
  • a flame-retardant composition comprising at least one copolyamide which is a polymerization product of at least one diamine, at least one dimer acid, at least one lactam and at least one organic flame-retardant additive; and a pro cess for preparing said composition.
  • the invention also discloses the use of said flame-re tardant composition for the preparation of fibres, carpets, packaging films, laminated multi layer films and insulation coating for wires and cables.
  • polyamides are of particular industrial significance, since they feature desirable mechan ical properties such as high strength and toughness, good chemical stability and high abra sion resistance. They are used, for example, for the production of fishing lines, climbing ropes and carpet backings. In addition, polyamides are employed for the production of packaging films, packaging sleeves and as an insulation coating for conducting wires.
  • GB 1 208 865 discloses a flame-retardant nylon composition
  • a flame-retardant nylon composition comprising 45 to 90 weight per cent of nylon, 0 to 45 weight per cent of fil ler, 5 to 30 weight per cent of zinc oxide and 5 to 25 weight per cent of a halogenated organic additive which acts synergistically with zinc oxide to improve the flame resistance of the composition.
  • the composition is thermally stable at the fabrication temperature of the nylon, but releases hydrogen halide at flame tempera tures.
  • the use of halogenated additives is no longer desired as flame-retardant component.
  • US 5,618,605 discloses a method for producing halogen-free, antimony-free and phospho rous-free polyamide fibers by incorporating an additive into the polyamide.
  • the additive con tains (1) a thermoplastic matrix polymer, (2) silicones in an amount between about 5% to about 20%, based on the total weight of the additive, and (3) a platinum complex catalyst
  • desired mechanical properties are reflected by tensile strength values of the composition containing the flame-retardant additive above 70 % of the composition without the flame-retardant additive and elongation at break values of the composition containing the flame-retardant additive above 80% of the composition without the flame-retardant additive without flame-retardant.
  • the first aspect of the presently claimed invention is directed to a flame-retard- ant composition
  • a flame-retard- ant composition comprising:
  • the at least one polyamide copolymer is a polymerization product of
  • (A2) 16.0 % to 85.0 % by weight of a monomer mixture comprising the following components: (A2a) at least one C 3 2-C 40 dimer acid and
  • the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VI II),
  • R 4 and R 2 are independently selected from formula (la);
  • R 3 and R 4 are independently selected from H and formula (la);
  • R 5 and R 6 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl
  • R 7 and R 8 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n 1 to 10
  • Rg and R 10 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl;
  • R n and R 12 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n is a number from 2 to 14;
  • the presently claimed invention is directed to a process for preparing a flame-retardant composition comprising the steps of:
  • step b extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets; wherein the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
  • R j and R 2 are independently selected from formula (la);
  • R 3 and R 4 are independently selected from H and formula (la);
  • R 5 and R 6 are independently selected from unsubstituted or substituted, linear or branched C 1-12 alkyl
  • R 7 and R 8 are independently selected from unsubstituted or substituted, linear or branched C 1-12 alkyl and unsubstituted or substituted C 3- 10 cycloalkyl,
  • n 1 to 10
  • Rg and R 10 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl;
  • R n and R 12 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n is a number from 2 to 14;
  • the presently claimed invention is directed to the use of the flame-retardant composition for the preparation of multilayer polymer films, fibers, carpets, or insulation coat ing over a conductor
  • the presently claimed invention is directed to a fiber comprising the flame- retardant composition.
  • the presently claimed invention is directed to a carpet comprising:
  • the presently claimed invention is directed to a method for manufacturing a flame-retardant carpet.
  • the presently claimed invention is directed to a laminated multilayer polymer film comprising at least one layer comprising the flame-retardant composition.
  • the presently claimed invention is directed to a process for producing a flame-resistant laminated multilayer polymer film.
  • the presently claimed invention is directed to a wire or a cable comprising a conductor coated with at least one layer comprising the flame-retardant composition.
  • the presently claimed invention is directed to a wire or cable comprising a conductor directly coated with a layer comprising the flame-retardant composition.
  • a group is defined to comprise at least a certain number of embodiments, this is meant to also encompass a group which preferably consists of these embodiments only.
  • the terms 'first', 'second', 'third' or 'a', ' b', 'o', etc. and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the presently claimed invention described herein are capable of operation in other sequences than described or illustrated herein.
  • the presently claimed invention is directed to a flame-retardant com position comprising:
  • the total amount of (A) and (B) is in the range of > 85.1 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition, wherein the at least one polyamide copolymer is a polymerization product of (Al) 15.0 % to 84.0 % by weight of at least one lactam,
  • (A2) 16.0 % to 85.0 % by weight of a monomer mixture comprising the following components: (A2a)at least one C 3 2-C 40 dimer acid and
  • the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (III), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
  • R 3 and R 4 are independently selected from H and formula (la);
  • R 5 and R 6 are independently selected from unsubstituted or substituted, linear or branched Ci_i 2 alkyl;
  • R 7 and R 8 are independently selected from unsubstituted or substituted, linear or branched Ci_i 2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n 1 to 10
  • Rg and R 10 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl;
  • R n and R 12 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n is a number from 2 to 14;
  • the flame-retardant composition comprises
  • (B) at least one organic flame-retardant additive in the range of > 0.5 to ⁇ 15.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 85.5 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition,.
  • the flame-retardant composition comprises
  • (B) at least one organic flame-retardant additive in the range of > 0.5 to ⁇ 12.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 88.5 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition, .
  • the flame-retardant composition comprises
  • (B) at least one organic flame-retardant additive in the range of > 0.5 to ⁇ 10.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 90.5 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition,.
  • the flame-retardant composition comprises
  • (B) at least one organic flame-retardant additive in the range of > 0.8 to ⁇ 10.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 90.8 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition,.
  • the flame-retardant composition comprises
  • (B) at least one organic flame-retardant additive in the range of > 0.8 to ⁇ 9.5 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 91.3 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition,.
  • the flame-retardant composition comprising:
  • the flame-retardant composition further comprises at least one additive selected from melamine or melamine derivatives.
  • the flame-retardant composition comprises
  • (B) at least two organic flame-retardant additives in the range of > 0.5 to ⁇ 15.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 85.5 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition,.
  • the flame-retardant composition comprises
  • (B) at least two organic flame-retardant additives in the range of > 0.5 to ⁇ 12.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 88.5 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition,.
  • the flame-retardant composition comprises
  • (B) at least two organic flame-retardant additives in the range of > 1.0 to ⁇ 10.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 91.0 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition,.
  • the flame-retardant composition comprises
  • (B) at least two organic flame-retardant additives in the range of > 2.0 to ⁇ 10.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 92.0 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition,.
  • the flame-retardant composition comprises
  • (B) at least two organic flame-retardant additives in the range of > 5.0 to ⁇ 9.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amou nt of (A) and (B) is in the range of > 96.0 to ⁇ 100 % by weight based on the overal l weight of the flame-retardant composition,.
  • the at least one polyamide copolymer is a polymerization product of (Al) 15.0 % to 84.0 % by weight of at least one lactam,
  • the component (Al) is at least one lactam.
  • the com ponent (Al) is at least one lactam having 4 to 12 carbon atoms.
  • the com ponent (Al) is at least one lactam having 5 to 8 carbon at oms.
  • the com ponent (Al) is at least one lactam which is u nsubstituted or sub stituted.
  • the substituent on the at least one lactam is independently selected from the group consisting of Ci_i 0 al kyl, C 5-6 cycloal kyl and C 5-10 aryl.
  • the suitable Ci-io al kyl su bstituents are, for example, selected from methyl, ethyl, propyl, isopropyl, n- butyl, sec-butyl and tert-butyl.
  • the suitable C 5-6 cycloal kyl su bstituent is cyclohexyl.
  • the C 5-10 aryl su bstituents are selected from phenyl and naphthyl.
  • the u nsubstituted lactams are selected from y - lactam ( y -butyrolactam), d -lactam ( d -valerolactam) and e -lactam ( e -caprolactam) .
  • the u nsubstituted lactams are selected from d -lactam ( d -valerolactam) .
  • the u nsubstituted lactam is e -lactam ( e -caprolactam) .
  • the e -lactam is e -caprolactam.
  • the com ponent (Al) is selected from 3-aminopropanolactam (propio-3-lactam; b -lactam; b -propiolactam) , 4-aminobutanolactam (butyro-4-lactam; y - lactam; y -butyrolactam) , 5-aminopentanolactam (2-piperidinone; 5 -lactam; 5 -valerolac tam) , 6-aminohexanolactam (hexano-6-lactam: e -lactam; e -caprolactam), 7-aminoheptanolactam (heptano-7-lactam; z -lactam; z -heptanolactam),
  • the component (Al) is selected from 3-aminopropanolactam, 4-aminobutanolactam, 5-aminopentanolactam, 6-aminohexanolactam,
  • A2 is a monomer mixture comprising the following components:
  • (A2b) at least one C 4 -C 12 diamine.
  • A2 is present in the range from 45.0 to 55.0 mol% of component (A2a) and in the range from 45.0 to 55.0 mol% of component (A2b), based in each case on the sum total of the molar percentages of components (A2a) and (A2b), based on the total molar amount of component (A2).
  • the A2 is present in the range from 47.0 to 53.0 mol% of component (A2a) and in the range from 47.0 to 53.0 mol% of component (A2b), based in each case on the sum total of the molar percentages of components (A2a) and (A2b), based on the total molar amount of component (A2).
  • the A2 is present in the range from 49.0 to 51.0 mol% of component (A2a) and in the range from 49.0 to 51.0 mol% of component (A2b), ), based in each case on the sum total of the molar percentages of com ponents (A2a) and (A2b), based on the total molar amount of component (A2).
  • the A2 is present in the range from 45.0 to 55.0 mol% of component (A2a) and in the range from 45.0 to 55.0 mol% of component (A2b), based in each case on the total molar amount of component (A2).
  • the sum total of the molar percentages of components (A2a) and (A2b) present in component (A2) typically adds up to 100.0 mol%.
  • the component (A2) may also additionally comprise a compo nent (A2c) which is at least one C 4 -C 20 diacid.
  • the at least one C 4 -C 20 diacid is selected from succinic acid, glutaric acid, adipic acid, heptanedioic acid, octanedioic acid, nonanedioic acid, decanedioic acid, un- decanedioic acid, dodecanedioic acid, tridecanedioic acid, tetradecanedioic acid, pentade- canedioic acid, hexadecanedioic acid, heptadecanedioic acid, octadecanedioic acid, nonade- canedioic acid, icosanedioic acid, maleic acid, fumaric acid, glutaconic acid, 2-decenedioic acid, dodec-2-enedioic acid, muconic acid, glutinic acid, citraconic acid, mesaconic acid and ita
  • the component (A2) comprises the component (A2a) in the range from 25.0 to 54.9 mol%, the component (A2b) in the range from 45.0 to 55.0 mol% of and the component (A2c) in the range from 0.1 to 25.0 mol%, based on the total molar amount of component (A2).
  • the component (A2) comprises the component (A2a) in the range from 13.0 to 52.9 mol%, the component (A2b) in the range from 47.0 to 53.0 mol% and the component (A2c) in the range from 0.1 to 13.0 mol%, based on the total molar amount of component (A2).
  • the component (A2) comprises the component (A2a) in the range from 7.0 to 50.9 mol%, the component (A2b) in the range from 49.0 to 51.0 mol% and the component (A2c) in the range from 0.1 to 7.0 mol% of, based on the total molar amount of component (A2).
  • component (A2) additionally comprises component (A2c)
  • the molar percentages of components (A2a), (A2b) and (A2c) typically add up to 100.0 mole percent.
  • the component (A2) additionally comprises water.
  • component (A2) may comprise components (A2a) and (A2b) and optionally (A2c) in fully reacted form, in partly reacted form or in unreacted form.
  • component (A2) comprises components (A2a) and (A2b) and optionally (A2c) in unreacted form.
  • “in unreacted form” thus means that the component (A2a) is present in the form of at least one C 3 2-C 40 dimer acid and the compo nent (A2b) is present in the form of at least one C 4 -C 12 diamine and the component (A2c) is present in the form of at least one C 4 -C 20 diacid.
  • the dimer acids are also referred to as dimer fatty acids.
  • the C 32 -C 40 dimer acids are prepared by dimerization of unsaturated fatty acids. This dimerization can be catalyzed, for example, by aluminas.
  • the component (A2a) is prepared from at least one unsaturated fatty acid selected from unsaturated C 16 fatty acids, unsaturated C 18 fatty acids and unsaturated C 20 fatty acids. I n another embodiment, the component (A2a) is prepared from unsaturated C 18 fatty acids.
  • the unsaturated C 16 fatty acid is palmitoleic acid ((9Z)-hexadeca-9-enoic acid).
  • the unsaturated C 18 fatty acids are selected from petroselic acid ((6Z)- octadeca-6-enoic acid), oleic acid ((9Z)-octadeca-9-enoic acid), elaidic acid ((9E)-octadeca- 9-enoic acid), vaccenic acid ((llE)-octadeca-ll-enoic acid), linoleic acid ((9Z,12Z)-octa- deca-9,12-dienoic acid), alpha-linolenic acid ((9Z,12Z,15Z)-octadeca-9,12,15-trienoic acid), gamma-linolenic acid ((6Z,9Z,12Z)-octadeca-6,9,12-trienoic acid), calendic acid ((8E,10E,12Z)-octadeca-8,10,12-
  • the unsaturated C 18 fatty acids selected from petroselic acid ((6Z)-octadeca-6-enoic acid), oleic acid ((9Z)-octadeca-9-enoic acid), elaidic acid ((9E)-octadeca-9-enoic acid), vaccenic acid ((llE)-octadeca-ll-enoic acid) and linoleic acid ((9Z,12Z)-octadeca-9,12-dienoic acid).
  • the unsaturated C 20 fatty acids are selected from gadoleic acid ((9Z)-eicosa-9-enoic acid), eicosenoic acid ((llZ)-eicosa-ll-enoic acid), arachidonic acid ((5Z,8Z,llZ,14Z)-eicosa-5,8,ll,14-tetraenoic acid) and timnodonic acid ((5Z,8Z,llZ,14Z,17Z)-eicosa-5,8,ll,14,17-pentaenoic acid).
  • the component (A2a) is at least one C 36 dimer acid.
  • the at least one C 36 dimer acid is prepared from the unsaturated C 13 fatty acids.
  • the C 36 dimer acid is prepared from the C 13 fatty acids selected from petroselic acid ((6Z)-octadeca-6-enoic acid), oleic acid ((9Z)-octa- deca-9-enoic acid), elaidic acid ((9E)-octadeca-9-enoic acid), vaccenic acid ((llE)-octa- deca-ll-enoic acid) and linoleic acid ((9Z,12Z)-octadeca-9,12-diensaure).
  • trimer acids may additionally form; residues of unreacted unsaturated fatty acid may also remain in the component A2a.
  • trimer acids is known to those skilled in the art.
  • the component (A2a) comprises not more than 0.5% by weight of unre acted unsaturated fatty acid and not more than 0.5% by weight of trimer acid. In another embodiment, the component (A2a) comprises not more than 0.2% by weight of unreacted unsaturated fatty acid and not more than 0.2% by weight of trimer acid, based in each case on the total weight of component (A2a).
  • the dimeric acids refer to a mixture that is prepared by oligomerization of unsaturated fatty acids. They are prepared, for example, by catalytic dimerization of unsaturated C 16 to C 20 fatty acids from vegetable sources.
  • the addi tion is primarily of the Diels-Alder type, and the result, according to the number and position of the double bonds in the fatty acids used for preparation of the dimer acids, is mixtures of primarily dimeric products having cycloaliphatic, linear aliphatic, branched aliphatic and also C 6 -aromatic hydrocarbyl groups between the carboxyl groups.
  • the aliphatic radicals may be saturated or unsatu rated, and the proportion of aromatic groups may also vary.
  • the radicals between the carbox ylic acid groups in that case comprise, for example, 32 to 40 carbon atoms.
  • the radicals that connect the carboxyl groups of the dimer fatty acids do not have any unsaturated bonds or any aromatic hydrocarbyl rad icals.
  • the C 18 fatty acids selected from linolenic acid, linoleic acid and oleic acid are preferably used for the preparation
  • the oligomerization described above gives rise to mixtures comprising mainly the dimeric molecules, but also the trimeric molecules and also the mon omeric molecules and other by-products.
  • the purification is typically by distillation means.
  • dimer acids consisting of dimeric fatty acid mole cules to an extent of at least 90.0 % by weight.
  • dimer acids consisting of dimeric fatty acid molecules to an extent of at least 95.0 % by weight.
  • dimer acids consisting of dimeric fatty acid molecules to an extent of at least 98.0 % by weight.
  • the proportions of monomeric, dimeric and trimeric molecules and other by-products in the dimer acids can be determined, for example, by means of gas chromatography (GC).
  • GC gas chromatography
  • the dimer acids here, prior to the GC analysis, are converted to the corresponding methyl esters via the boron trifluoride method (of. DIN EN ISO 5509) and then analyzed by means of GC.
  • Component (A2a) has an acid number, for example, in the range from 190.0 to 200.0 mg KOH/g.
  • the component (A2b) is at least one C 4 -C 12 diamine.
  • the compound“C 4 -C 12 diamine” are aliphatic and/or aromatic compounds having four to twelve carbon atoms and two amino groups (-NH 2 groups).
  • the aliphatic and/or aromatic compounds may be unsubstituted or substituted. If the aliphatic and/or aromatic compounds are substituted, the number of sub stituents is one, two or more substituents that do not take part in the polymerization of com ponents (Al) and (A2).
  • the substituents are selected from alkyl or cycloalkyl substituents.
  • the at least one C 4 -C 12 diamine is unsubstituted.
  • the components (A2b) are selected from 1,4-diaminobutane (butane-1, 4- diamine; tetramethylenediamine; putrescine), 1,5-diaminopentane (pentamethylenediamine; pentane-1, 5-diamine; cadaverine), 1,6-diaminohexane (hexamethylenediamine; hexane-1, 6- diamine), 1,7-diaminoheptane, 1,8-diaminoctane, 1,9-diaminononane, 1,10-diaminodecane (decamethylenediamine), 1,11-diaminoundecane (undecamethylenediamine) and 1,12-dia- minododecane (dodecamethylenediamine).
  • the component (A2b) is selected from tetramethylenediamine, pentamethylenediamine, hex
  • the copolyamide is prepared by polymerizing 30.0 % to 83.0 % by weight of component (Al) and from 17.0 % to 70.0 % by weight of component (A2), wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2).
  • the copolyamide is prepared by polymerizing from 40.0 % to 80.0 % by weight of component (Al) and 20.0 % to 60.0 % by weight of component (A2), wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2).
  • the copolyamide is prepared by pol ymerizing from 60.0 % to 80.0 % by weight of component (Al) and 20.0 % to 40.0 % by weight of component (A2), wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2).
  • the copolyamide is prepared by polymerizing components (Al) and (A2).
  • the polymerization of components (Al) and (A2) is known to those skilled in the art.
  • the polymerization of components (Al) with (A2) is a condensation reaction.
  • the component (Al) reacts with the components (A2a) and (A2b) that are present in the component (A2) and with any component (A2c) as described above or below that may likewise be present in component (A2).
  • Amide bonds are being formed between the individual components during the reaction.
  • component (Al) is at least partly pre sent in open-chain form during the polymerization, i.e. in the form of an amino acid.
  • the polymerization of components (Al) and (A2) takes place in the pres ence of a catalyst or in the absence of a catalyst.
  • Suitable catalysts are al l catalysts that are known to those skilled in the art and catalyze the polymerization of components (Al) and (A2).
  • Catalysts (A2c) of this kind are known to those skilled in the art.
  • the catalysts are phosphorus compounds, for example sodium hypophosphite, phosphorous acid, triphenylphosphine or triphenyl phosphite.
  • the polymerization of components (Al) and (A2) forms the copolyamide, which therefore receives structural units derived from component (Al) and structural units derived from component (A2).
  • the structural units derived from com ponent (A2) comprise structural units derived from components (A2a), (A2b) and from any component (A2c).
  • the component (Al) is 6-aminohexanolactam
  • the component (A2a) is C 36 dimer acid
  • the component (A2b) is hexamethylenediamine.
  • the copolyamide is a random copolymer.
  • the copolyamidecopolyamide has a glass transition temperature in the range of> 20 to ⁇ 50 °C. In yet another embodiment, the copolyamide has a glass transi tion temperature in the range of > 23 to ⁇ 47 °C. In still another embodiment, the copolyamide has a glass transition temperature in the range of> 25 to ⁇ 45 °C, each case determined according to ISO 11357-2:2014. The glass transition temperature is based on the dray copol yamide. In the context of the presently claimed invention,“dry” means that the copolyamide comprises less than 1 % by weight of water, based on the total weight of the copolyamide.
  • the copolyamidecopolyamide has a viscosity number in the range of> 150 to ⁇ 300 ml_/g, determined in a 0.5% by weight solution of the copolyamide in a mixture of phenol/o-dichlorobenzene in a weight ratio of 1:1.
  • the copoly amide has a viscosity number in the range of> 160 to ⁇ 290 ml_/g, determined in a 0.5% by weight solution of the copolyamide in a mixture of phenol/o-dichlorobenzene in a weight ratio of 1:1.
  • the copolyamide has a viscosity number in the range of> 170 to ⁇ 280 ml_/g, determined in a 0.5% by weight solution of the copolyamide in a mixture of phenol/o-dichlorobenzene in a weight ratio of 1:1
  • the composition of the presently claimed invention comprises at least one organic flame- retardant additive.
  • the at least one organic flame-retardant additive (B) is selected from mel amine, melamine derivatives, N-alkoxy piperidines amine derivatives of formula (I), com- pounds of formula (II), compounds of formula (III), compounds of formula (IV), compounds of formula (V), compounds of formula (VI), compounds of formula (VI I) and compounds of for mula (VI II),
  • R j and R 2 are independently selected from formula (la);
  • R 3 and R 4 are independently selected from H and formula (la);
  • R 5 and R 6 are independently selected from unsubstituted or substituted, linear or branched Ci_i alkyl
  • R 7 and R 8 are independently selected from unsubstituted or substituted, linear or branched Ci_i alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n 1 to 10
  • Rg and R 10 are independently selected from unsubstituted or substituted, linear or branched Ci_i alkyl;
  • R n and R 12 are independently selected from unsubstituted or substituted, linear or branched Ci_i alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n is a number from 2 to 14;
  • R 5 and R 6 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl. I n another embodiment, R 5 and R 6 are independently selected from unsubstituted or substituted, linear or branched Ci_ 8 alkyl. In still another embodiment, R 5 and R 6 are independently selected from unsubstituted or substituted, linear Ci_ 8 alkyl. In yet another embodiment, R 5 and R 6 is unsubstituted linear Ci_ 6 alkyl.
  • R 7 and R 8 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl.
  • R 7 and Rg are independently selected from unsubstituted or substituted, linear or branched Ci_i 0 alkyl and unsubstituted or substituted C 3-8 cycloalkyl.
  • R 7 and R 8 are independently selected from unsubstituted or substituted, linear or branched Ci_ 8 alkyl and unsubstituted or substituted C 5-8 cycloalkyl.
  • the unsubstituted, linear or branched C 1A2 alkyl is selected from methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl and dodecyl.
  • the unsubstituted branched C 1A2 alkyl is selected from 1-methyl ethyl, 1- methyl propyl, 2-methyl propyl, 1-methyl butyl, 2-methyl butyl, 3-methyl butyl, 1-methyl pen tyl, 2-methyl pentyl, 3-methyl pentyl, 4-methyl pentyl, 1-methyl hexyl, 2-methyl hexyl, 3-me- thyl hexyl, 4-methyl hexyl, 5-methyl hexyl, 1-methyl heptyl, 2-methyl heptyl, 3-methyl heptyl, 4-methyl heptyl, 5-methyl heptyl, 6-methyl heptyl, 1-methyl octyl, 2-methyl octyl, 3-methyl octyl, 4-methyl octyl, 5-methyl octyl, 6-methyl octyl, 7-methyl octyl, 1-methyl nonyl,
  • R 5 and R 6 are substituted, linear or branched C 1A2 alkyl, wherein the sub stituents are selected from anime, hydroxy, alkoxy, ester and keto.
  • unsubstituted or substituted C 3-8 cycloal kyl is selected from cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, bicyc I o [2.2.1] heptyl and bicyclo[3.1.1]heptyl.
  • substituted C 3-8 cycloalkyl is cycloalkyl with one or more equal or different alkyl groups such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, n-pentyl, iso-pentyl, neo-pentyl etc.
  • the representative examples of branched C 3 -C 10 monocyclic and bicyclic cy cloalkyl include, but are not limited to, methyl cyclohexyl, dimethyl cyclohexyl etc.
  • the melamine derivatives are selected from melamine cyanurate, mela mine polyphosphate, dimelamine phosphate, melamine pyrophosphate, melamine borate, melamine ammonium polyphosphate and melamine ammonium pyrophosphate.
  • the N-alkoxy piperidines amine derivatives of formula (I) are selected from N,N',N , "-tris ⁇ 2,4-bis[(l-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]-s-tri- azin-6-yl ⁇ -3,3'-ethylenedii mi nodi propylamine; N,N',N"-tris ⁇ 2,4-bis[(l-cyclohexyloxy-2, 2,6,6- tetramethy I pi peridi n -4-yl) n -buty lam i no] -s-triazin-6-yl ⁇ -3,3'-ethylenedii mi nodi propylamine; N,N',N"'-tris ⁇ 2,4-bis[(l-octyloxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino
  • the at least one organic flame-retardant additive is present in the range of > 0.1 to ⁇ 15.0 % by weight, based on the overal l weight of the flame-retardant composi tion. I n another embodiment, the at least one organic flame-retardant additive is present in the range of > 0.5 to ⁇ 15.0 % by weight, based on the overall weight of the flame-retardant composition. In still in an embodiment, the at least one organic flame-retardant additive is present in the range of > 1 to ⁇ 15 % by weight, based on the overall weight of the flame- retardant composition. In still in another embodiment, the at least one organic flame-retard- ant additive is present in the range of > 1 to ⁇ 12 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one organic flame-retardant additive is melamine or its deriv atives.
  • the at least one melamine or its derivatives has a particle size ⁇ 15 micron. I n an embodiment, the at least one melamine or its derivatives are present in the range of > 0.1 to ⁇ 15.0 % by weight, based on the overall weight of the flame-retardant composition. In another embodiment, the at least one melamine or its derivatives are present in the range of > 0.5 to ⁇ 15.0 % by weight, based on the overall weight of the flame-retardant composition. In still an embodiment, the at least one melamine or its derivatives are present in the range of > 1.0 to ⁇ 15.0 % by weight, based on the overal l weight of the flame-retardant composi tion.
  • the at least one melamine or its derivatives are present in the range of > 1.0 to ⁇ 12.0 % by weight, based on the overall weight of the flame-retardant composition. In yet in an embodiment, the at least one melamine or its derivatives are present in the range of > 1.0 to ⁇ 10.0 % by weight, based on the overall weight of the flame-retardant composition. In yet another embodiment, the at least one melamine or its derivatives are present in the range of > 1.0 to ⁇ 8.0 % by weight, based on the overall weight of the flame- retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to ⁇ 15.0 % by weight, based on the overall weight of the flame- retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to ⁇ 12.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to ⁇ 9.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to ⁇ 9.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine deriva tive of formula (I) is present in the range of > 0.5 to ⁇ 8.0 % by weight, based on the overal l weight of the flame-retardant composition.
  • the at least one N- alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to ⁇ 3.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to ⁇ 2.0 % by weight, based on the overal l weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) and the at least one melamine derivative are present in the range of > 0.1 to ⁇ 15.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) and the at least one mela mine derivative are present in the range of > 0.5 to ⁇ 15.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N- alkoxy piperidines amine derivative of formula (I) and the at least one melamine derivative are present in the range of > 0.5 to ⁇ 12.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piper idines amine derivative of formula (I) and the at least one melamine derivative are present in the range of > 0.5 to ⁇ 11.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine deriva tive of formula (I) and the at least one melamine derivative are present in the range of > 0.5 to ⁇ 10.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) and the at least one melamine derivative are present in the range of > 0.5 to ⁇ 9.0 % by weight, based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to ⁇ 5.0 % by weight and the at least one melamine derivatives is present in the range of > 3.0 to ⁇ 12.0 % by weight, each based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to ⁇ 3.0 % by weight and the at least one melamine derivative is present in the range of > 5.0 to ⁇ 10.0 % by weight, each based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to ⁇ 2.5 % by weight and the at least one melamine derivative is present in the range of > 6.0 to ⁇ 9.0 % by weight, each based on the overall weight of the flame-retardant com position.
  • the at least one N-alkoxy piperidines amine deriva tive of formula (I) is present in the range of > 0.5 to ⁇ 2.0 % by weight and the at least one melamine derivative is present in the range of > 7.0 to ⁇ 9.0 % by weight, each based on the overall weight of the flame-retardant composition.
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.8 to ⁇ 1.5 % by weight and the at least one melamine derivative is present in the range of
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in an amount of 1.0 % by weight and the at least one melamine derivative is present in an amount 8.0 % by weight, each based on the overall weight of the flame- retardant composition.
  • At least one polyamide copolymer is present in the range of > 83.0 to ⁇ 96.9 % by weight
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to ⁇ 5.0 % by weight
  • the at least one melamine derivative is present in the range of > 3.0 to ⁇ 12.0 % by weight, each based on the overall weight of the flame-retardant composition.
  • At least one polyamide copolymer is present in the range of > 87.0 to ⁇ 94.5 % by weight
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to ⁇ 3.0 % by weight
  • the at least one melamine derivative is present in the range of > 5.0 to ⁇ 10.0 % by weight, each based on the overall weight of the flame-retardant composition.
  • At least one polyamide copolymer is present in the range of > 88.0 to ⁇ 93.2 % by weight
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to ⁇ 2.5 % by weight
  • the at least one melamine derivative is present in the range of
  • At least one polyamide copolymer is present in the range of > 81.0 to ⁇ 92.2 % by weight
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to ⁇ 2.0 % by weight and the at least one melamine derivative is present in the range of > 7.0 to ⁇ 9.0 % by weight, each based on the overall weight of the flame-retardant composition
  • at least one polyam ide copolymer is present in the range of > 90.0 to ⁇ 91.7 % by weight
  • the at least one N- alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.8 to ⁇ 1.5 % by weight
  • the at least one melamine derivative is present in the range of > 7.5 to ⁇ 8.5 % by weight, each based on
  • At least one polyamide copolymer is present in an amount of 91.0 % by weight
  • the at least one N-alkoxy piperidines amine derivative of formula (I) is present in an amount of 1.0 % by weight
  • the at least one melamine derivative is present in an amount of 8.0 % by weight, each based on the overall weight of the flame-retardant compo sition.
  • the presently claimed invention is directed to a process for preparing a composition comprising the steps of:
  • step b extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets.
  • the presently claimed invention is directed to a process for preparing a composition comprising the steps of:
  • step b extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets.
  • the presently claimed invention is directed to a process for pre paring a composition comprising the steps of:
  • the presently claimed invention is directed to a process for preparing a composition comprising the steps of:
  • step b extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets.
  • the presently claimed invention is directed to a process for pre paring a composition comprising the steps of:
  • step b extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets.
  • the at least one organic flame-retardant is dissolved in a solvent prior to mixing with at least one polyamide copolymer.
  • the at least one melamine or its derivatives is dissolved in a solvent prior to mixing with at least one polyamide copolymer.
  • the mixing in step a. is performed at a temperature in the range of > 20.0 to ⁇ 150.0 °C.
  • the mixing step a. is performed at a temperature in the range of > 30.0 to ⁇ 150.0 °C.
  • the mixing step a. is performed at a temperature in the range of > 50.0 to ⁇ 150.0 °C.
  • the mixing step a. is performed at a temperature in the range of > 80.0 to ⁇ 150.0 °C.
  • the mixing step a. is performed at a temperature in the range of > 100.0 to ⁇ 150.0 °C.
  • the extrusion step b. is performed at a temperature in the range of > 20.0 to ⁇ 450.0 °C.
  • the extrusion step b. is performed at a temperature in the range of > 100.0 to ⁇ 350.0 °C.
  • the extrusion step b. is per formed at a temperature in the range of > 150.0 to ⁇ 300.0 °C.
  • the extrusion step b. is performed at a temperature in the range of > 180.0 to ⁇ 280.0 °C. in still in another embodiment, the extrusion step b. is performed at a temperature in the range of > 180.0 to ⁇ 250.0 °C.
  • the presently claimed invention is directed to the use of the flame-retard- ant composition as described above for the preparation of multilayer polymer films, fibers or carpets In an embodiment, the presently claimed invention is directed to fibers made from the flame- retardant composition as defined above.
  • the term“fiber” refers to filamentous material that can be used in fabric and yarn as well as textile fabrication.
  • One or more fibers can be used to produce a fabric or yarn.
  • the yarn can be fully drawn or textured according to methods known in the art.
  • the face fibers can include bulked continuous filament (BCF) or staple fibers for tufted or woven carpets.
  • fibrous substrate includes, but is not limited to, textiles, carpets, apparel, furniture coverings, drapes, upholstery, bed ding, automotive seat covers, and the like, that include fibers or yarns.
  • fibrous substrates can include air-craft fibrous substrates such as air-craft textiles, air-craft carpets, air-craft seat covering, and the like. It should be noted that embodiments of the present disclosure can include fibrous substrates that are non-woven fabrics or needle felt.
  • the term“carpet” may refer to a struc ture including face fiber and a backing.
  • a primary backing may have a yarn tufted through the primary backing.
  • the underside of the primary backing can include one or more layers of material (e.g., coating layer, a secondary backing, and the like) to cover the backstitches of the yarn.
  • a tufted carpet includes a pile yarn, a primary backing, a lock coat, and a secondary backing.
  • a woven carpet includes a pile yarn, a warp, and weft skele ton onto which the pile yarn is woven, and a backing.
  • Embodiments of the carpet can include woven, non-woven, and needle felts.
  • a needle felt can include a backing with fibers attached as a non-woven sheet.
  • a non-woven covering can include backing and a face side of different or similar materials.
  • the presently claimed invention is directed to a carpet comprising:
  • the presently claimed invention is directed to a carpet comprising: i) a pile yarn comprising the flame-retardant composition;
  • pile yarn comprising the flame-retardant composition having a limiting oxygen index of 26.0 or more; the backing fabric having a limiting oxygen index of 26.0 or more; and the latex having a limiting oxygen index of 26.0 or more.
  • the backing fabric having the limiting oxygen index of 26.0 or more is formed by coating or impregnating the backing fabric containing polyester fiber with the latex having the limiting oxygen index of 26.0 or more and curing the latex.
  • the carpet according to presently claimed invention, wherein the backing fabric contains polyester fiber contains polyester fiber.
  • the carpet according to presently claimed invention wherein the flame- retardant composition of the pile yarn further contains a heat stabilizer.
  • the carpet according to presently claimed invention wherein the at least one heat stabilizer is selected from at least one hindered phenolic compound and at least one hindered amine compounds.
  • the at least one hindered phenolic compound and/or the at least one hindered amine compound are selected from N,N-hexamethylenebis(3,5-di-t-butyl-4-hydrox- yphenyl) propionate, 1,3-benzene dicarboxyamide and N,N' -bis(2,2,6,6-tetramethyl-4-pi- peridinyl).
  • the at least one heat stabilizer is present in the flame-retardant nylon in the range of 0.1 to 1.0% by weight, based on the total weight of the flame-retardant nylon.
  • the carpet according to presently claimed invention wherein the flame- retardant composition for the pile yarn contains at least one flow stability improver.
  • the at least one flow stability improver is a metal salt of a fatty acid.
  • the at least one flow stability improver is selected from magnesium stea rate, montanic acid magnesium, magnesium behenate, magnesium 12-hydroxystearate and calcium stearate, amide ethylene-bis-stearate and amide ethylene-bis-behenate.
  • the at least one flow stability improver is present in the flame-retardant nylon in the range of 0.1 to 1.0% by weight, based on the total weight of the flame-retardant nylon.
  • the latex having the limiting oxygen index of 26.0 or more is obtained by blending 30.0 to 200.0 parts by weight of expanded graphite and/or 10.0 to 100.0 parts by weight of at least one flame-retardant with 100.0 parts by weight of a latex component.
  • the at least one flame-retardant is phosphoric flame retardant.
  • the carpet according to presently claimed invention, wherein the flame- retardant composition comprises at least one flow stability improver is selected from magne sium stearate, magnesium montanic acid, magnesium behenate, magnesium 12-hydroxys- tearate, calcium stearate, amide ethylene-bis-stearate and amide ethylene-bis-behenate.
  • the presently claimed invention is directed to a method for manufacturing a carpet comprising the steps of: i) a tufting step of implanting piles of the yarn comprising the flame- retardant composition as described above;
  • the presently claimed invention is directed to a method for manufacturing a carpet comprising the steps of:
  • the presently claimed invention is directed to a method for manufacturing a carpet comprising the steps of:
  • the nylon pile yarn having a limiting oxygen index of 26.0 or more is pre pared from a flame-retardant composition as defined above.
  • the pile yarn containing nylon has the limiting oxygen index of 26.0 or more
  • the backing fabric containing polyester fiber has the limiting oxygen index of 26.0 or more
  • the latex for binding the pile yarn to the backing fabric has the limiting oxygen index of 26.0 or more. Since each of the materials composing the carpet has high flame retardance such that the limiting oxygen index is 26.0 or more as described above, the flame-retardant nylon carpet is fit to be used in a vessel, a vehicle, an aircraft, a movie theater, a theater, a welfare facility and a tall building and having high flame retardance is realized regardless of using a nylon BCF for the pile yarn.
  • the presently claimed invention is directed to a laminated multilayer pol ymer film comprising at least one layer comprising the flame-retardant composition as de fined above.
  • the laminated multilayer polymer film comprising
  • the laminated multilayer polymer film comprising
  • the presently claimed invention is directed to a laminated multi layer polymer film comprising:
  • the presently claimed invention is directed to a laminated multi layer polymer film comprising:
  • the at least one polymer layer is made from a polymer selected from pol yolefins, poly(ethylene-vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene tereph- thalates, polyvinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and iono- mers.
  • presently claimed invention is directed to a process for producing a lami nated multilayer polymer film, comprising the steps of
  • one film in step i) comprises the flame-retardant composition as defined above; and the other film or films comprise at least one polymer selected from polyolefins, polyethylene- vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers.
  • the films or polymer layers may be obtained by a film extrusion or co extrusion process, casting process, blowing process or a biaxially orientation process, usually in the course of an extrusion process.
  • the biaxially orientation process usually in the course of an extrusion process is preferred in case of polyethylene terephthalates, yielding so called biaxially oriented PET films (“boPET films”).
  • the preparation of films from a flame-retardant composition as defined above and/or the at least one further polymer (FP) of polyolefins, poly(ethylene-vinyl alco hols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers may include stretching or bi axial orientation.
  • the stretching is performed by any methods known to those skilled in the art.
  • the polymer film of the said polymers is stretched by guiding it over at least one roll, preferably a roll system, or by extending it widthwise. If said polymer film is obtained in the form of a tube, it is likewise possible that said polymer film is stretched by blowing air into the tube of the said polymer film and hence stretching the polymer film. It will be appreciated that combinations of the methods are also possible.
  • the said polymer film is guided over at least one roll, preferably through a roll system, the polymer film is stretched in extrusion direction, i.e. lengthwise. If the said polymer film, by contrast, is extended widthwise, it is stretched at right angles to extrusion direction.
  • the said polymer film, for stretching is guided over at least one roll, pref erably through a roll system, the polymer chains of the at least one polyamide copolymer comprising the flame-retardant as described above or at least one further polymer are aligned parallel to the direction in which stretching is performed.
  • the stretched polymer film obtained is then uniaxially oriented.
  • the stretched polymer film obtained is likewise uniaxially oriented when the said polymer film, for stretching, is extended widthwise.
  • the poly mer chains of the at least one polyamide copolymer comprising the flame-retardant as de scribed above and of at least one further polymer are aligned parallel to the direction in which stretching is performed.
  • uniaxially oriented means that the polymer chains are aligned essentially in one direction
  • the said polymer film, for stretching is guided over a roll system and ad ditionally extended widthwise, the polymer chains of the at least one polyamide copolymer comprising the flame-retardant as described above and of any at least one further polymer are aligned parallel to both directions in which stretching is performed.
  • the stretched polymer film obtained is then biaxial ly oriented.
  • “biaxial ly oriented” means that the polymer chains are aligned essentially in two different directions, preferably at right angles to one another. I n an embodiment, if the above-described processes for stretching the said polymer film are combined, the polymer film is thus obtained, for example, in tubular form and the polymer fil m is stretched by blowing air into the tube of the polymer fil m and simultaneously guided over rolls and likewise stretched; thus, the stretched polymer film (SP) obtained is biaxially oriented.
  • the said polymer film is typically stretched at a temperature above the glass transition temperature (T g ) of the at least one copolyamide and below the melting tem perature (T m of the at least one copolyamide. If the said polymer film is a multilayer film, it is also preferable that the polymer film is stretched at a temperature below the melting temper ature (Tj of the at least one further polymer, especially preferably at a temperature below the melting temperature of the at least one further polymer having the lowest melting tem perature.
  • the layers of aluminum metal or tin metal in the laminated film are usually obtained by applying a rolled foil or sheet, of aluminum metal and/or tin metal
  • the term“layer” in relation to laminated multilayer polymer containing film means either (i) a single layer, gen erally an extruded film, of the at least one copolyamide and/or a single layer, generally an extruded fil m, of the at least one further polymer and/or a single layer, generally in the form of a rolled foil or sheet, of aluminum and/or tin metal or (ii) more than one layers, generally co-extruded films, of the at least one copolyamide and/or more than one layers, generally co extruded fil ms, of the at least one further polymer and/or a more than one layers, generally in the form of a rolled foil or sheet, of aluminum metal and/or tin metal.
  • Laminating of films generally polymer films, mostly thermoplastic polymer films, is well known in the art.
  • Lamination is usually understood as the bonding of substrates of large surface area, more particularly for the production of composite films using suitable lamination adhesives includ ing adhesive polymers which may be formulated with typical auxiliaries.
  • suitable lamination adhesives included ing adhesive polymers which may be formulated with typical auxiliaries.
  • at least two films are usually bonded with one another using a lamination adhesive.
  • the lamination adhesive is usually applied to the large-surface-area substrates to be bonded such as films from a copolyamide as de fined herein and/or films of the at least one further polymer of polyolefins, poly(ethylene- vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers and/or aluminum metal and/or tin metal, preferably with an adhesive layer thickness of 0.1 to 20.0 g/m 2 , more preferably 1.0 to 7.0 g/m 2 , by means, for example, of knife coating, spreading, etc.
  • a copolyamide as de fined herein and/or films of the at least one further polymer of polyolefins, poly(ethylene- vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinylidene chlorides, maleic anhydride
  • Typical coating techniques may be employed, examples being roller coating, reverse roller coating, gravure roller coating, reverse gravure roller coating, brush coating, rod coating, spray coating, air brush coating, meniscus coating, curtain coating or dip coating.
  • the coated substrate may then be laminated with a second substrate, the temperature can be, for example, 20.0 to 200.0 ° C, preferably 20.0 to 100.0 ° C, and the pressure can be, for example, 100.0 to 3000.0 kN/m 2 , preferably 300.0 to 2000.0 kN/m 2 .
  • the lamination adhesive may be employed as a one-component composition, i.e. without ad ditional crosslinking agents or as a two-component composition including at least one cross- linking agent such as for example isocyanate crosslinkers.
  • At least one of the fil ms may be metalized or printed on the side that is coated with adhesive.
  • the stated films and foils may be bonded with one another or with a foil or film of a different type - for example, polymer films with metal foils, different polymer films with one another, etc.
  • the stated foils and films may also, for example, be printed with printing inks.
  • the lamination adhesives useful for the lamination process according to the invention are the ones known in the art and they are preferably non-tacky. Lamination adhesives are distin guished from pressure-sensitive adhesive in that they have no or only very low tack at room temperature and are applied with pressure and at elevated temperatures.
  • the tack as meas ured as so called Loop Tack is preferably less than 1,7 N/25 mm (adhesive coating weight of 20.0 pm on a 12.0 pm PET-film, measured on steel at 20.0 ° C with a delamination speed of 300.0 mm/min).
  • the lamination adhesives useful for the lamination process according to the invention are for example based on adhesive polymers dissolved in organic solvents or in the form of aqueous dispersions comprising at least one adhesive polymer dispersed in aqueous medium.
  • Pre ferred dispersion adhesives are aqueous dispersions of polyacrylates or aqueous dispersions of polyurethanes.
  • the adhesive polymers of the lamination adhesives may be polymers ob tainable by radical polymerization of ethylenically unsaturated compounds (monomers) or may be polymers obtainable by polycondensation, such as polyurethanes, for example.
  • Suit able adhesive polymers are more particularly poly(meth)acrylates, ethylene/vinyl acetate co polymer, polyurethanes, polyamide resins, saturated polyesters, polyolefins, styrene/butadi ene block copolymers, styrene/isoprene block copolymers, polyimides, PVC, and polyvinylpyr rolidone.
  • the presently claimed invention is directed to the use of a laminated mul tilayer polymer film as packaging film.
  • the laminated film of the invention can be used as tubular pouch packag ing, as laterally sealed pouch packaging, as thermoformed packaging, for closable pouches and/or as cushion packaging.
  • the laminated film (P) contains aluminium metal, usually as at least one inner layer(s) of the laminated film (P), it is used as retortable packaging film.
  • the presently claimed invention is directed to a wire or a cable comprising a conductor coated with at least one layer comprising the flame-retardant composition as defined above.
  • the wire or cable comprising a conductor directly coated with a layer comprising the flame-retardant composition as defined above.
  • the flame-retardant composition as described above for the wire or the cable further contains at least one heat stabilizer selected from at least one hindered phenolic compound and at least one hindered amine compounds.
  • the at least one hindered phenolic compound and/or the at least one hindered amine compound is selected from, but not limited to, N,N-hexamethylenebis(3,5-di- t-butyl-4-hydroxyphenyl) propionate, 1,3-benzene dicarboxyamide, N,N' -bis(2,2,6,6-tetra- methyl-4-piperidinyl), pentaerythritol tetra kis(3- (3, 5-d i-tert-buty I -4- hydroxy phenyl) propio nate (Irganox 1010) and 2',3-bis [[3- [3,5-di-tert-butyl-4-hyd roxyphenyl] propionyl]] propion- ohydrazide (Irganox 1024 MD).
  • the wire or the cable according to presently claimed invention wherein the flame-retardant composition as described above forms a coating around the conductor.
  • I n an embodiment, the wire or the cable according presently claimed invention, wherein the conductor is a copper metal core.
  • the copper metal core may have a size of 0.1 to 25.0 mm 2 .
  • the insulation layer is of a thickness in the range of > 0.2 to ⁇ 1.3 mm. In yet another embodiment, the insulation layer is of a thickness in the range of > 0.2 to ⁇ 1.0 mm. In still another embodiment the insulation layer is of a thickness in the range of > 0.2 to ⁇ 0.8 mm. I n another embodiment, the insulation layer is of a thickness in the range of > 0.2 to ⁇ 0.5 mm.
  • the presently claimed invention is directed to a process of forming an insulation coating around the conducting wire or the cable.
  • the flame-retardant composition as defined above is applied using any conventional coating techniques.
  • a typical procedure is to apply the composition by extruding a substantially uniform layer onto a metal conductor.
  • the extrusion may be carried out using a single screw extruder at the desired line speeds.
  • the curing of the coating is typically accomplished by passing the insu lated wire through a pressurized steam tube immediately following extrusion.
  • the wire or the cable of the invention pass the ISO 6722 test either at 125.0 ° C, or 150.0 ° C. In another embodiment, the wire or the cable of the invention pass the ISO 6722 test at 125.0 ° C and 150.0 ° C.
  • the ISO 6722 test There are three categories of cable which can be subjected to the ISO test 6722: thick wall, thin wall or ultra-thin wall. They are categorised based on the insulation thickness in relation to the conductor diameter and size. The thinner the wal l, the more challenging it is to pass the ageing standard.
  • the wire or the cable of the invention passes a heat ageing measured according to ISO 6722 (thin wall cables as above) at 125.0 ° C of at least 3000 hrs.
  • the wire or the cable of the invention passes a heat ageing measured according to ISO 6722 (thin wall cables as above) at 150.0 ° C of at least 240 hrs.
  • a flame-retardant composition comprising:
  • (B) at least one organic flame-retardant additive in the range of > 0.1 to ⁇ 15.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 85.1 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition,
  • the at least one polyamide copolymer is a polymerization product of
  • the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
  • R 4 and R 2 are independently selected from formula (la);
  • R 3 and R 4 are independently selected from H and formula (la);
  • R 5 and R 6 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl
  • R 7 and R 8 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n 1 to 10
  • Rg and R 10 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl;
  • R n and R 12 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n is a number from 2 to 14;
  • the flame-retardant composition according to embodiment 1 or 2 further comprises at least one organic flame-retardant (C) selected from melamine and melamine deriva tives.
  • C organic flame-retardant
  • melamine derivatives are selected from melamine cyanurate, melamine polyphosphate, dimelamine phosphate, melamine pyrophosphate, melamine borate, melamine ammo nium polyphosphate and melamine ammonium pyrophosphate.
  • organic flame-retardant (C) is present in an amount in the range of > 5.0 to ⁇ 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of >90.1 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition.
  • N-alkoxy piperidines amine derivatives of formula (I) are selected from N,N',N'"- tris2,4-bis[(l-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]-s-triazin- 6-y I -3, 3'-ethylenedii mi nodi propylamine; N,N',N"-tris2,4-bis[(l-cyclohexyloxy-2,2,6,6- tetramethyl pi perid in -4-yl) n-butylami no] -s-triazin-6-yl -3, 3'-ethy lenedii mi nodi propyla mine; N,N',N"'-tris2,4-bis[(l-octyloxy-2,2,6,6-tetramethylpiperidin-4-yla mine; N,N',N"'-tris2,4-bis[(l
  • the component (Al) is selected from 3-aminopropanolactam, 4-aminobutanolactam, 5-aminopentanolactam, 6-aminohexanolactam, 7-aminoheptanolactam, 8-aminooc- tanolactam, 9-aminononanolactam, 10-aminodecan
  • component (A2) comprises in the range from 45.0 to 55.0 mol % of component (A2a) and in the range from 45.0 to 55.0 mol % of component (A2b), based in each case on the total molar amount of component (A2).
  • the flame-retardant composition according to any of the embodiments 1 to 10 wherein the at least one polyamide copolymer is a random copolymer.
  • At least one polyamide copolymer (A) is present in an amount the range of > 85.0 to ⁇ 94.9 % by weight, based on the overall weight of the flame-retardant composi tion;
  • At least one organic flame-retardant additive (B) is present in the range of > 0.1 to ⁇ 5.0 % by weight, based on the overal l weight of the flame-retardant composition;
  • At least one organic flame-retardant additive (C) is present in an amount in the range of > 5.0 to ⁇ 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of >90.1 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition.
  • a process for preparing a composition according to any of the embodiments 1 to 13 comprising the steps of:
  • step b extruding the homogenous mixture obtained in step a. to provide a solution com prising pellets
  • the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
  • R 3 and R 4 are independently selected from H and formula (la);
  • R 5 and R 6 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl
  • R 7 and R 8 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n 1 to 10
  • Rg and R 10 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl;
  • R n and R 12 are independently selected from unsubstituted or substituted, linear or branched C 1A2 alkyl and unsubstituted or substituted C 3-10 cycloalkyl,
  • n is a number from 2 to 14;
  • the process according to any of the embodiments 14 to 15 further comprises at least one organic flame-retardant (C) selected from melamine and melamine derivatives.
  • melamine derivatives are se lected from melamine cyanurate, melamine polyphosphate, dimelamine phosphate, melamine pyrophosphate, melamine borate, melamine ammonium polyphosphate and melamine ammonium pyrophosphate.
  • organic flame- retardant (C) is present in an amount in the range of > 5.0 to ⁇ 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of > 90.1 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition.
  • At least one polyamide copolymer (A) is present in an amount the range of > 85.0 to ⁇ 94.9 % by weight, based on the overall weight of the flame-retardant composi tion;
  • At least one organic flame-retardant additive (B) is present in the range of > 0.1 to ⁇ 5.0 % by weight, based on the overal l weight of the flame-retardant composition;
  • At least one organic flame-retardant additive (C) is present in an amount in the range of > 5.0 to ⁇ 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of > 90.1 to ⁇ 100 % by weight based on the overall weight of the flame-retardant composition.
  • Fibers comprising the flame-retardant composition according to any of the embodi ments 1 to 13.
  • a carpet comprising:
  • the at least one flow stability improver is selected from magnesium stearate, magnesium montanic acid, magnesium behenate, magnesium 12-hydroxystearate, calcium stearate, amide ethylene-bis-stearate and amide ethylene-bis-behenate.
  • Method for manufacturing a carpet according to any of the embodiments 23 to 28 com prising the steps of:
  • a laminated multilayer polymer film comprising at least one layer comprising the flame- retardant composition according to any of the embodiments 1 to 13.
  • the at least one polymer is selected from polyolefins, poly(ethylene-vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinylidene chlo rides, maleic anhydride-grafted polyolefins, polyesters and ionomers.
  • a process for producing a laminated multilayer polymer film according to any of the embodiments embodiment 30 or 32 comprising the steps of
  • one film in step i) comprises the flame-retardant composition according to any of the embodiments 1 to 13; and the other film or films comprise at least one polymer selected from polyolefins, poly(eth- ylene-vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, poly- vinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers.
  • a wire or cable comprising a conductor coated with at least one layer comprising the flame-retardant composition according to any of the embodiments 1 to 13.
  • a wire or cable comprising a conductor directly coated with a layer comprising the flame-retardant composition according to any of the embodiments 1 to 13.
  • NOR 116 CAS 191680-81-6 commercially available and purchased from BASF under the trade name FLAM ESTAB NOR 116 ® .
  • Melapure MC is a salt of melamine and cyanuric acid available from BASF under the trade name Melapure MC ® .
  • Pripol ® 1009 C 36 hydrogenated dimer acid is commercially available from Croda.
  • the elongation at break is determined according to ASTM D882-10.
  • the tensile strength is determined according to ASTM D882-10.
  • the weight loss is determined according to NFPA-701.
  • the pellets of the copolyamide obtained were extracted with water at 95° C for 4 x 6 hours and then dried at 90° C to 140° C in a nitrogen stream for 10 hours.
  • the copolyamide obtained had a viscosity number of 259 ml_/g, a glass transition temperature of 38 °C and a melting temperature of 188 °C.
  • Table 1 The examples of flame-retardant copolyamide compositions
  • the examples 2-6 were prepared by blending the copolyamide and the flame-retardant component and extrusion.
  • Examples 1 to 3 Screw speed 100 RPM; Feeder speed 125; pelletizer speed 10.
  • Tensile strength and elongation at break for present invention is calculated as value given in percentage of example 1.
  • the tensile strength values above 70 % of the comparative example without flame-re tardant and elongation at break values above 80% of the comparative example without flame- retardant show acceptable mechanical properties.
  • the at least one polyamide copolymer comprising the at least one organic flame-retardant additive retains desirable mechanical properties while adding additional flame-retardant properties.

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Abstract

The presently claimed invention is directed to a flame-retardant composition comprising a copolyamide of a diamine, a dimer acid, a lactam and at least one organic flame-retardant additive; and a process for preparing said composition. The invention also discloses the use of said flame-retardant copolyamide composition in preparing fibres, carpets, packaging films, laminated multilayer films and insulation coating for wire or cable.

Description

A FLAME-RETARDANT COMPOSITION
FILED OF INVENTION
The presently claimed invention is directed to a flame-retardant composition comprising at least one copolyamide which is a polymerization product of at least one diamine, at least one dimer acid, at least one lactam and at least one organic flame-retardant additive; and a pro cess for preparing said composition. The invention also discloses the use of said flame-re tardant composition for the preparation of fibres, carpets, packaging films, laminated multi layer films and insulation coating for wires and cables.
BACKGROUND OF INVENTION
The polyamides are of particular industrial significance, since they feature desirable mechan ical properties such as high strength and toughness, good chemical stability and high abra sion resistance. They are used, for example, for the production of fishing lines, climbing ropes and carpet backings. In addition, polyamides are employed for the production of packaging films, packaging sleeves and as an insulation coating for conducting wires.
GB 1 208 865 discloses a flame-retardant nylon composition comprising 45 to 90 weight per cent of nylon, 0 to 45 weight per cent of fil ler, 5 to 30 weight per cent of zinc oxide and 5 to 25 weight per cent of a halogenated organic additive which acts synergistically with zinc oxide to improve the flame resistance of the composition. The composition is thermally stable at the fabrication temperature of the nylon, but releases hydrogen halide at flame tempera tures. The use of halogenated additives is no longer desired as flame-retardant component.
US 5,618,605 discloses a method for producing halogen-free, antimony-free and phospho rous-free polyamide fibers by incorporating an additive into the polyamide. The additive con tains (1) a thermoplastic matrix polymer, (2) silicones in an amount between about 5% to about 20%, based on the total weight of the additive, and (3) a platinum complex catalyst
Flowever, these additives do not show sufficient effectiveness in the nylon chemistry. Be sides, the high loading that is required to achieve sufficient flame-retardant properties com promises on the mechanical properties of the polyamide. Another disadvantage of many com mon flame-retardant additives is their particle size which is too large to withstand the pro cessing requirements.
Thus, it is an object of the presently claimed invention to provide a copolyamide composition having flame-retardant properties while maintaining the desired mechanical properties of polyamides of the prior art such as flexibility etc. SUMMARY OF INVENTION
Surprisingly, it has been found that adding at least one organic flame-retardant additive in a specific amount to a copolyamide composition having a high content of long-chain aliphatic moieties can improve the flame-retardant properties of polyamides while maintaining the de sired mechanical properties of the polyamides of the prior art such as flexibility etc..
In the context of the presently claimed invention, desired mechanical properties are reflected by tensile strength values of the composition containing the flame-retardant additive above 70 % of the composition without the flame-retardant additive and elongation at break values of the composition containing the flame-retardant additive above 80% of the composition without the flame-retardant additive without flame-retardant.
Accordingly, the first aspect of the presently claimed invention is directed to a flame-retard- ant composition comprising:
(A) at least one polyamide copolymer in an amount the range of > 85.0 to < 99.9 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least one organic flame-retardant additive in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition;
wherein the total amount of (A) and (B) is in the range of > 85.1 to <100 % by weight based on the overall weight of the flame-retardant composition
wherein the at least one polyamide copolymer is a polymerization product of
(Al) 15.0 % to 84.0 % by weight of at least one lactam,
(A2) 16.0 % to 85.0 % by weight of a monomer mixture comprising the following components: (A2a) at least one C32-C40 dimer acid and
(A2b)at least one C4-C12 diamine,
wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2);
wherein the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VI II),
Figure imgf000003_0001
formula (I),
wherein R4 and R2 are independently selected from formula (la);
R3 and R4 are independently selected from H and formula (la);
Figure imgf000004_0001
R5 and R6 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
R7 and R8 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000004_0002
wherein
m is 1 to 10,
Rg and R10 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
Rn and R12 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000005_0001
wherein n is a number from 2 to 14;
Figure imgf000005_0002
formula (V);
Figure imgf000006_0001
I n a second aspect, the presently claimed invention is directed to a process for preparing a flame-retardant composition comprising the steps of:
a. mixing at least one polyamide copolymer in an amount the range of > 85.0 to < 99.9 % by weight, based on the overall weight of the flame-retardant composition; and at least one organic flame-retardant additive in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition to obtain a homogenous mix ture; wherein the total amount of (A) and (B) is in the range of > 85.1 to <100 % by weight based on the overall weight of the flame-retardant composition, and
b. extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets; wherein the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
Figure imgf000007_0001
formula (I),
wherein Rj and R2 are independently selected from formula (la);
R3 and R4 are independently selected from H and formula (la);
Figure imgf000007_0002
R5 and R6 are independently selected from unsubstituted or substituted, linear or branched C1-12 alkyl;
R7 and R8 are independently selected from unsubstituted or substituted, linear or branched C1-12 alkyl and unsubstituted or substituted C3- 10 cycloalkyl,
Figure imgf000008_0001
wherein
m is 1 to 10,
Rg and R10 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
Rn and R12 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000008_0002
wherein n is a number from 2 to 14;
Figure imgf000009_0001
Figure imgf000010_0001
In a third aspect, the presently claimed invention is directed to the use of the flame-retardant composition for the preparation of multilayer polymer films, fibers, carpets, or insulation coat ing over a conductor
In a fourth aspect, the presently claimed invention is directed to a fiber comprising the flame- retardant composition.
In a fifth aspect, the presently claimed invention is directed to a carpet comprising:
i) a pile yarn comprising the flame-retardant composition; and
ii) latex used for binding the pile yarn to the backing fabric.
In a sixth aspect, the presently claimed invention is directed to a method for manufacturing a flame-retardant carpet.
In a seventh aspect, the presently claimed invention is directed to a laminated multilayer polymer film comprising at least one layer comprising the flame-retardant composition.
I n an eighth aspect, the presently claimed invention is directed to a process for producing a flame-resistant laminated multilayer polymer film.
I n a ninth aspect, the presently claimed invention is directed to a wire or a cable comprising a conductor coated with at least one layer comprising the flame-retardant composition.
In a tenth aspect, the presently claimed invention is directed to a wire or cable comprising a conductor directly coated with a layer comprising the flame-retardant composition.
Detailed Description
Before the present compositions and formulations of the presently claimed invention are de scribed, it is to be understood that this invention is not limited to particular compositions and formulations described, since such compositions and formulation may, of course, vary. It is also to be understood that the terminology used herein is not intended to be limiting, since the scope of the presently claimed invention will be limited only by the appended claims.
If hereinafter a group is defined to comprise at least a certain number of embodiments, this is meant to also encompass a group which preferably consists of these embodiments only. Furthermore, the terms 'first', 'second', 'third' or 'a', ' b', 'o', etc. and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the presently claimed invention described herein are capable of operation in other sequences than described or illustrated herein. In case the terms 'first', 'second', 'third' or '(A)', '(B)' and '(C)' or '(a)', '(b)', '(c)', '(d)', V, 'ϋ' etc. relate to steps of a method or use or assay there is no time or time interval coherence between the steps, that is, the steps may be carried out sim ultaneously or there may be time intervals of seconds, minutes, hours, days, weeks, months or even years between such steps, unless otherwise indicated in the application as set forth herein above or below.
Furthermore, the ranges defined throughout the specification include the end values as well i.e. a range of 1 to 10 implies that both 1 and 10 are included in the range. For the avoidance of doubt, applicant shall be entitled to any equivalents according to applicable law.
In the following passages, different aspects of the presently claimed invention are defined in more detail. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being pre ferred or advantageous.
Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the presently claimed invention. Thus, appearances of the phrases 'in one embodiment' or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment but may.
Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while some embodiments described herein include some, but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the presently claimed invention, and form different embodiments, as would be understood by those in the art. For example, in the appended claims, any of the claimed embodiments can be used in any combination.
I n a first embodiment, the presently claimed invention is directed to a flame-retardant com position comprising:
(A) at least one polyamide copolymer in an amount the range of > 85.0 to < 99.9 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least one organic flame-retardant additive in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition;
wherein the total amount of (A) and (B) is in the range of > 85.1 to <100 % by weight based on the overall weight of the flame-retardant composition, wherein the at least one polyamide copolymer is a polymerization product of (Al) 15.0 % to 84.0 % by weight of at least one lactam,
(A2) 16.0 % to 85.0 % by weight of a monomer mixture comprising the following components: (A2a)at least one C32-C40 dimer acid and
(A2b)at least one C4-C12 diamine,
wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2);
wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2);
wherein the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (III), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
Figure imgf000012_0001
formula (I), wherein R4 and R2 are independently selected from formula (la);
R3 and R4 are independently selected from H and formula (la);
Figure imgf000012_0002
R5 and R6 are independently selected from unsubstituted or substituted, linear or branched Ci_i2 alkyl;
R7 and R8 are independently selected from unsubstituted or substituted, linear or branched Ci_i2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000013_0001
wherein
m is 1 to 10,
Rg and R10 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
Rn and R12 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000013_0002
wherein n is a number from 2 to 14;
Figure imgf000013_0003
Figure imgf000014_0001
In an embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amou nt the range of > 85.0 to < 99.5 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least one organic flame-retardant additive in the range of > 0.5 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 85.5 to <100 % by weight based on the overall weight of the flame-retardant composition,.
In another embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amou nt the range of > 88.0 to < 99.5 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least one organic flame-retardant additive in the range of > 0.5 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 88.5 to <100 % by weight based on the overall weight of the flame-retardant composition, .
Yet another embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amou nt the range of > 90.0 to < 99.5 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least one organic flame-retardant additive in the range of > 0.5 to < 10.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 90.5 to <100 % by weight based on the overall weight of the flame-retardant composition,.
Still another embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amou nt the range of > 90.0 to < 99.2 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least one organic flame-retardant additive in the range of > 0.8 to < 10.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 90.8 to <100 % by weight based on the overall weight of the flame-retardant composition,.
Yet in a particular embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amou nt the range of > 90.5 to < 99.2 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least one organic flame-retardant additive in the range of > 0.8 to < 9.5 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 91.3 to <100 % by weight based on the overall weight of the flame-retardant composition,.
Still in a particular embodiment, the flame-retardant composition comprising:
(A) at least one polyamide copolymer in an amou nt the range of > 91.0 to < 99.0 % by weight, based on the overall weight of the flame-retardant composition; and (B) at least one organic flame-retardant additive in the range of > 1.0 to < 9.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 92.0 to <100 % by weight based on the overall weight of the flame-retardant composition,.
In another preferred embodiment, the flame-retardant composition further comprises at least one additive selected from melamine or melamine derivatives.
In another preferred embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amount the range of > 85.0 to < 99.5 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least two organic flame-retardant additives in the range of > 0.5 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 85.5 to <100 % by weight based on the overall weight of the flame-retardant composition,.
In another preferred embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amount the range of > 88.0 to < 99.5 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least two organic flame-retardant additives in the range of > 0.5 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 88.5 to <100 % by weight based on the overall weight of the flame-retardant composition,.
Yet another preferred embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amount the range of > 90.0 to < 99.0 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least two organic flame-retardant additives in the range of > 1.0 to < 10.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 91.0 to <100 % by weight based on the overall weight of the flame-retardant composition,.
Still another preferred embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amount the range of > 90.0 to < 98.0 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least two organic flame-retardant additives in the range of > 2.0 to < 10.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 92.0 to <100 % by weight based on the overall weight of the flame-retardant composition,.
Yet in a preferred embodiment, the flame-retardant composition comprises
(A) at least one polyamide copolymer in an amount the range of > 90.5 to < 97.0 % by weight, based on the overall weight of the flame-retardant composition; and (B) at least two organic flame-retardant additives in the range of > 3.0 to < 9.5 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amou nt of (A) and (B) is in the range of > 93.5 to <100 % by weight based on the overal l weight of the flame-retardant composition,.
Stil l in a preferred embodiment, the flame-retardant com position com prising:
(A) at least one polyamide copolymer in an amou nt the range of > 91.0 to < 95.0 % by weight, based on the overal l weight of the flame-retardant composition; and
(B) at least two organic flame-retardant additives in the range of > 5.0 to < 9.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amou nt of (A) and (B) is in the range of > 96.0 to <100 % by weight based on the overal l weight of the flame-retardant composition,.
I n an em bodiment, the at least one polyamide copolymer is a polymerization product of (Al) 15.0 % to 84.0 % by weight of at least one lactam,
(A2) 16.0 % to 85.0 % by weight of a monomer mixtu re
wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2) .
I n an embodiment, the component (Al) is at least one lactam.
I n an embodiment, the com ponent (Al) is at least one lactam having 4 to 12 carbon atoms. I n another em bodiment, the com ponent (Al) is at least one lactam having 5 to 8 carbon at oms.
I n an embodiment, the com ponent (Al) is at least one lactam which is u nsubstituted or sub stituted. The substituent on the at least one lactam is independently selected from the group consisting of Ci_i0 al kyl, C5-6 cycloal kyl and C5-10 aryl. I n an alternate embodiment, the suitable Ci-io al kyl su bstituents are, for example, selected from methyl, ethyl, propyl, isopropyl, n- butyl, sec-butyl and tert-butyl. I n another embodiment, the suitable C5-6 cycloal kyl su bstituent is cyclohexyl. I n an alternate embodiment, the C5-10 aryl su bstituents are selected from phenyl and naphthyl.
I n an embodiment, the u nsubstituted lactams are selected from y - lactam ( y -butyrolactam), d -lactam ( d -valerolactam) and e -lactam ( e -caprolactam) . I n another embodiment, the u nsubstituted lactams are selected from d -lactam ( d -valerolactam) . I n an alternate embod iment, the u nsubstituted lactam is e -lactam ( e -caprolactam) .
I n an alternate embodiment, the e -lactam is e -caprolactam.
I n an embodiment, the com ponent (Al) is selected from 3-aminopropanolactam (propio-3-lactam; b -lactam; b -propiolactam) , 4-aminobutanolactam (butyro-4-lactam; y - lactam; y -butyrolactam) , 5-aminopentanolactam (2-piperidinone; 5 -lactam; 5 -valerolac tam) , 6-aminohexanolactam (hexano-6-lactam: e -lactam; e -caprolactam), 7-aminoheptanolactam (heptano-7-lactam; z -lactam; z -heptanolactam),
8-aminooctanolactam (octano-8-lactam; ^ -lactam; h -octanolactam),
9-aminononanolactam (nonano-9-lactam; Q -lactam; Q -nonanolactam),
10-aminodecanolactam (decano-10-lactam; w -decanolactam), 11-aminoundecanolactam (undecano-ll-lactam; w -undecanolactam) and 12-aminododecanolactam (dodecano-12- lactam; w -dodecanolactam).
In still another embodiment, the component (Al) is selected from 3-aminopropanolactam, 4-aminobutanolactam, 5-aminopentanolactam, 6-aminohexanolactam,
7-aminoheptanolactam, 8-aminooctanolactam, 9-aminononanolactam,
10-aminodecanolactam, 11-aminoundecanolactam and 12-aminododecanolactam.
In an embodiment, A2 is a monomer mixture comprising the following components:
(A2a) at least one C32-C40 dimer acid and
(A2b)at least one C4-C12 diamine.
In an embodiment, A2 is present in the range from 45.0 to 55.0 mol% of component (A2a) and in the range from 45.0 to 55.0 mol% of component (A2b), based in each case on the sum total of the molar percentages of components (A2a) and (A2b), based on the total molar amount of component (A2). In another embodiment, the A2 is present in the range from 47.0 to 53.0 mol% of component (A2a) and in the range from 47.0 to 53.0 mol% of component (A2b), based in each case on the sum total of the molar percentages of components (A2a) and (A2b), based on the total molar amount of component (A2). Still an embodiment, the A2 is present in the range from 49.0 to 51.0 mol% of component (A2a) and in the range from 49.0 to 51.0 mol% of component (A2b), ), based in each case on the sum total of the molar percentages of com ponents (A2a) and (A2b), based on the total molar amount of component (A2). Yet another embodiment, the A2 is present in the range from 45.0 to 55.0 mol% of component (A2a) and in the range from 45.0 to 55.0 mol% of component (A2b), based in each case on the total molar amount of component (A2). The sum total of the molar percentages of components (A2a) and (A2b) present in component (A2) typically adds up to 100.0 mol%.
In another embodiment, the component (A2) may also additionally comprise a compo nent (A2c) which is at least one C4-C20 diacid.
In another embodiment, the at least one C4-C20 diacid is selected from succinic acid, glutaric acid, adipic acid, heptanedioic acid, octanedioic acid, nonanedioic acid, decanedioic acid, un- decanedioic acid, dodecanedioic acid, tridecanedioic acid, tetradecanedioic acid, pentade- canedioic acid, hexadecanedioic acid, heptadecanedioic acid, octadecanedioic acid, nonade- canedioic acid, icosanedioic acid, maleic acid, fumaric acid, glutaconic acid, 2-decenedioic acid, dodec-2-enedioic acid, muconic acid, glutinic acid, citraconic acid, mesaconic acid and itaconic acid.
In an embodiment, the component (A2) comprises the component (A2a) in the range from 25.0 to 54.9 mol%, the component (A2b) in the range from 45.0 to 55.0 mol% of and the component (A2c) in the range from 0.1 to 25.0 mol%, based on the total molar amount of component (A2). In another embodiment, the component (A2) comprises the component (A2a) in the range from 13.0 to 52.9 mol%, the component (A2b) in the range from 47.0 to 53.0 mol% and the component (A2c) in the range from 0.1 to 13.0 mol%, based on the total molar amount of component (A2). Still another embodiment, the component (A2) comprises the component (A2a) in the range from 7.0 to 50.9 mol%, the component (A2b) in the range from 49.0 to 51.0 mol% and the component (A2c) in the range from 0.1 to 7.0 mol% of, based on the total molar amount of component (A2).
In an embodiment, when component (A2) additionally comprises component (A2c), the molar percentages of components (A2a), (A2b) and (A2c) typically add up to 100.0 mole percent.
In another embodiment, the component (A2) additionally comprises water.
I n an embodiment, the components (A2a) and (A2b) and optionally (A2c) of component (A2) react with one another to obtain amides. This reaction is known as such to those skilled in the art. Therefore, component (A2) may comprise components (A2a) and (A2b) and optionally (A2c) in fully reacted form, in partly reacted form or in unreacted form. I n another embodi ment, the component (A2) comprises components (A2a) and (A2b) and optionally (A2c) in unreacted form.
Within the context of the presently claimed invention,“in unreacted form” thus means that the component (A2a) is present in the form of at least one C32-C40 dimer acid and the compo nent (A2b) is present in the form of at least one C4-C12 diamine and the component (A2c) is present in the form of at least one C4-C20 diacid.
In another embodiment, the dimer acids are also referred to as dimer fatty acids. The C32-C40 dimer acids are prepared by dimerization of unsaturated fatty acids. This dimerization can be catalyzed, for example, by aluminas.
In an embodiment, the component (A2a) is prepared from at least one unsaturated fatty acid selected from unsaturated C16 fatty acids, unsaturated C18 fatty acids and unsaturated C20 fatty acids. I n another embodiment, the component (A2a) is prepared from unsaturated C18 fatty acids.
I n an embodiment, the unsaturated C16 fatty acid is palmitoleic acid ((9Z)-hexadeca-9-enoic acid).
In an embodiment, the unsaturated C18 fatty acids are selected from petroselic acid ((6Z)- octadeca-6-enoic acid), oleic acid ((9Z)-octadeca-9-enoic acid), elaidic acid ((9E)-octadeca- 9-enoic acid), vaccenic acid ((llE)-octadeca-ll-enoic acid), linoleic acid ((9Z,12Z)-octa- deca-9,12-dienoic acid), alpha-linolenic acid ((9Z,12Z,15Z)-octadeca-9,12,15-trienoic acid), gamma-linolenic acid ((6Z,9Z,12Z)-octadeca-6,9,12-trienoic acid), calendic acid ((8E,10E,12Z)-octadeca-8,10,12-trienoic acid), punicic acid ((9Z,llE,13Z)-octadeca-9,ll,13- trienoic acid), alpha-eleostearic acid ((9Z,llE,13E)-octadeca-9,ll,13-trienoic acid) and beta-eleostearic acid ((9E,llE,13E)-octadeca-9,ll,13-trienoic acid). In another embodiment, the unsaturated C18 fatty acids selected from petroselic acid ((6Z)-octadeca-6-enoic acid), oleic acid ((9Z)-octadeca-9-enoic acid), elaidic acid ((9E)-octadeca-9-enoic acid), vaccenic acid ((llE)-octadeca-ll-enoic acid) and linoleic acid ((9Z,12Z)-octadeca-9,12-dienoic acid).
In an embodiment, the unsaturated C20 fatty acids are selected from gadoleic acid ((9Z)-eicosa-9-enoic acid), eicosenoic acid ((llZ)-eicosa-ll-enoic acid), arachidonic acid ((5Z,8Z,llZ,14Z)-eicosa-5,8,ll,14-tetraenoic acid) and timnodonic acid ((5Z,8Z,llZ,14Z,17Z)-eicosa-5,8,ll,14,17-pentaenoic acid).
I n an embodiment, the component (A2a) is at least one C36 dimer acid.
I n an embodiment, the at least one C36 dimer acid is prepared from the unsaturated C13 fatty acids. In another embodiment, the, the C36 dimer acid is prepared from the C13 fatty acids selected from petroselic acid ((6Z)-octadeca-6-enoic acid), oleic acid ((9Z)-octa- deca-9-enoic acid), elaidic acid ((9E)-octadeca-9-enoic acid), vaccenic acid ((llE)-octa- deca-ll-enoic acid) and linoleic acid ((9Z,12Z)-octadeca-9,12-diensaure).
In an embodiment, while preparing the component (A2a) from the unsaturated fatty acids, trimer acids may additionally form; residues of unreacted unsaturated fatty acid may also remain in the component A2a. The formation of trimer acids is known to those skilled in the art.
In an embodiment, the component (A2a) comprises not more than 0.5% by weight of unre acted unsaturated fatty acid and not more than 0.5% by weight of trimer acid. In another embodiment, the component (A2a) comprises not more than 0.2% by weight of unreacted unsaturated fatty acid and not more than 0.2% by weight of trimer acid, based in each case on the total weight of component (A2a).
Within the context of the presently claimed invention, the dimeric acids refer to a mixture that is prepared by oligomerization of unsaturated fatty acids. They are prepared, for example, by catalytic dimerization of unsaturated C16 to C20 fatty acids from vegetable sources. The addi tion is primarily of the Diels-Alder type, and the result, according to the number and position of the double bonds in the fatty acids used for preparation of the dimer acids, is mixtures of primarily dimeric products having cycloaliphatic, linear aliphatic, branched aliphatic and also C6-aromatic hydrocarbyl groups between the carboxyl groups. According to the mechanism and/or any subsequent hydrogenation, the aliphatic radicals may be saturated or unsatu rated, and the proportion of aromatic groups may also vary. The radicals between the carbox ylic acid groups in that case comprise, for example, 32 to 40 carbon atoms. Preference is given to using fatty acids having 18 carbon atoms for the preparation, such that the dimeric product thus has 36 carbon atoms. Preferably, the radicals that connect the carboxyl groups of the dimer fatty acids do not have any unsaturated bonds or any aromatic hydrocarbyl rad icals. In another embodiment, the C18 fatty acids selected from linolenic acid, linoleic acid and oleic acid are preferably used for the preparation
Depending on the reaction regime, the oligomerization described above gives rise to mixtures comprising mainly the dimeric molecules, but also the trimeric molecules and also the mon omeric molecules and other by-products. The purification is typically by distillation means.
In an embodiment, it is preferable to use dimer acids consisting of dimeric fatty acid mole cules to an extent of at least 90.0 % by weight. In another embodiment, it is preferable to use dimer acids consisting of dimeric fatty acid molecules to an extent of at least 95.0 % by weight. In yet another embodiment, it is preferable to use dimer acids consisting of dimeric fatty acid molecules to an extent of at least 98.0 % by weight.
The proportions of monomeric, dimeric and trimeric molecules and other by-products in the dimer acids can be determined, for example, by means of gas chromatography (GC). The dimer acids here, prior to the GC analysis, are converted to the corresponding methyl esters via the boron trifluoride method (of. DIN EN ISO 5509) and then analyzed by means of GC.
Component (A2a) has an acid number, for example, in the range from 190.0 to 200.0 mg KOH/g.
I n an embodiment, the component (A2b) is at least one C4-C12 diamine.
Within the context of the presently claimed invention, the compound“C4-C12 diamine” are aliphatic and/or aromatic compounds having four to twelve carbon atoms and two amino groups (-NH2 groups). The aliphatic and/or aromatic compounds may be unsubstituted or substituted. If the aliphatic and/or aromatic compounds are substituted, the number of sub stituents is one, two or more substituents that do not take part in the polymerization of com ponents (Al) and (A2). The substituents are selected from alkyl or cycloalkyl substituents. In an embodiment, the at least one C4-C12 diamine is unsubstituted.
I n an embodiment, the components (A2b) are selected from 1,4-diaminobutane (butane-1, 4- diamine; tetramethylenediamine; putrescine), 1,5-diaminopentane (pentamethylenediamine; pentane-1, 5-diamine; cadaverine), 1,6-diaminohexane (hexamethylenediamine; hexane-1, 6- diamine), 1,7-diaminoheptane, 1,8-diaminoctane, 1,9-diaminononane, 1,10-diaminodecane (decamethylenediamine), 1,11-diaminoundecane (undecamethylenediamine) and 1,12-dia- minododecane (dodecamethylenediamine). I n another embodiment, the component (A2b) is selected from tetramethylenediamine, pentamethylenediamine, hexamethylenediamine, dec amethylenediamine and dodecamethylenediamine.
In another embodiment, the copolyamide is prepared by polymerizing 30.0 % to 83.0 % by weight of component (Al) and from 17.0 % to 70.0 % by weight of component (A2), wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2). In still another embodiment, the copolyamide is prepared by polymerizing from 40.0 % to 80.0 % by weight of component (Al) and 20.0 % to 60.0 % by weight of component (A2), wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2). In yet another embodiment, the copolyamide is prepared by pol ymerizing from 60.0 % to 80.0 % by weight of component (Al) and 20.0 % to 40.0 % by weight of component (A2), wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2).
In an embodiment, the copolyamide is prepared by polymerizing components (Al) and (A2). The polymerization of components (Al) and (A2) is known to those skilled in the art. Typically, the polymerization of components (Al) with (A2) is a condensation reaction. During the con densation reaction, the component (Al) reacts with the components (A2a) and (A2b) that are present in the component (A2) and with any component (A2c) as described above or below that may likewise be present in component (A2). Amide bonds are being formed between the individual components during the reaction. Typically, component (Al) is at least partly pre sent in open-chain form during the polymerization, i.e. in the form of an amino acid.
In an embodiment, the polymerization of components (Al) and (A2) takes place in the pres ence of a catalyst or in the absence of a catalyst. Suitable catalysts are al l catalysts that are known to those skilled in the art and catalyze the polymerization of components (Al) and (A2). Catalysts (A2c) of this kind are known to those skilled in the art. In another embodiment, the catalysts are phosphorus compounds, for example sodium hypophosphite, phosphorous acid, triphenylphosphine or triphenyl phosphite.
In an embodiment, the polymerization of components (Al) and (A2) forms the copolyamide, which therefore receives structural units derived from component (Al) and structural units derived from component (A2). In another embodiment, the structural units derived from com ponent (A2) comprise structural units derived from components (A2a), (A2b) and from any component (A2c).
In an embodiment, the component (Al) is 6-aminohexanolactam, the component (A2a) is C36 dimer acid and the component (A2b) is hexamethylenediamine.
In an embodiment, the copolyamide is a random copolymer.
In another embodiment, the copolyamidecopolyamide has a glass transition temperature in the range of> 20 to < 50 °C. In yet another embodiment, the copolyamide has a glass transi tion temperature in the range of > 23 to < 47 °C. In still another embodiment, the copolyamide has a glass transition temperature in the range of> 25 to < 45 °C, each case determined according to ISO 11357-2:2014. The glass transition temperature is based on the dray copol yamide. In the context of the presently claimed invention,“dry” means that the copolyamide comprises less than 1 % by weight of water, based on the total weight of the copolyamide. In another embodiment, the copolyamidecopolyamide has a viscosity number in the range of> 150 to < 300 ml_/g, determined in a 0.5% by weight solution of the copolyamide in a mixture of phenol/o-dichlorobenzene in a weight ratio of 1:1. In yet another embodiment, the copoly amide has a viscosity number in the range of> 160 to < 290 ml_/g, determined in a 0.5% by weight solution of the copolyamide in a mixture of phenol/o-dichlorobenzene in a weight ratio of 1:1. In still another embodiment, the copolyamide has a viscosity number in the range of> 170 to < 280 ml_/g, determined in a 0.5% by weight solution of the copolyamide in a mixture of phenol/o-dichlorobenzene in a weight ratio of 1:1 The composition of the presently claimed invention comprises at least one organic flame- retardant additive.
In an embodiment, the at least one organic flame-retardant additive (B) is selected from mel amine, melamine derivatives, N-alkoxy piperidines amine derivatives of formula (I), com- pounds of formula (II), compounds of formula (III), compounds of formula (IV), compounds of formula (V), compounds of formula (VI), compounds of formula (VI I) and compounds of for mula (VI II),
Figure imgf000023_0001
formula (I),
wherein Rj and R2 are independently selected from formula (la);
R3 and R4 are independently selected from H and formula (la);
Figure imgf000023_0002
R5 and R6 are independently selected from unsubstituted or substituted, linear or branched Ci_i alkyl;
R7 and R8 are independently selected from unsubstituted or substituted, linear or branched Ci_i alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000024_0001
formula (I I)
wherein
m is 1 to 10,
Rg and R10 are independently selected from unsubstituted or substituted, linear or branched Ci_i alkyl;
Rn and R12 are independently selected from unsubstituted or substituted, linear or branched Ci_i alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000024_0002
formula (I II)
wherein n is a number from 2 to 14;
Figure imgf000025_0001
Figure imgf000026_0001
In an embodiment, R5 and R6 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl. I n another embodiment, R5 and R6 are independently selected from unsubstituted or substituted, linear or branched Ci_8 alkyl. In still another embodiment, R5 and R6 are independently selected from unsubstituted or substituted, linear Ci_8 alkyl. In yet another embodiment, R5 and R6 is unsubstituted linear Ci_6 alkyl.
I n an embodiment, R7 and R8 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl. I n another em bodiment, R7 and Rg are independently selected from unsubstituted or substituted, linear or branched Ci_i0 alkyl and unsubstituted or substituted C3-8 cycloalkyl. In still another embodi ment, R7 and R8 are independently selected from unsubstituted or substituted, linear or branched Ci_8 alkyl and unsubstituted or substituted C5-8 cycloalkyl.
In an embodiment, the unsubstituted, linear or branched C1A2 alkyl is selected from methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl and dodecyl.
In an embodiment, the unsubstituted branched C1A2 alkyl is selected from 1-methyl ethyl, 1- methyl propyl, 2-methyl propyl, 1-methyl butyl, 2-methyl butyl, 3-methyl butyl, 1-methyl pen tyl, 2-methyl pentyl, 3-methyl pentyl, 4-methyl pentyl, 1-methyl hexyl, 2-methyl hexyl, 3-me- thyl hexyl, 4-methyl hexyl, 5-methyl hexyl, 1-methyl heptyl, 2-methyl heptyl, 3-methyl heptyl, 4-methyl heptyl, 5-methyl heptyl, 6-methyl heptyl, 1-methyl octyl, 2-methyl octyl, 3-methyl octyl, 4-methyl octyl, 5-methyl octyl, 6-methyl octyl, 7-methyl octyl, 1-methyl nonyl, 2-methyl nonyl, 3-methyl nonyl, 4-methyl nonyl, 5-methyl nonyl, 6-methyl nonyl, 7-methyl nonyl, 8- methyl nonyl, 1-methyl decyl, 2-methyl decyl, 3-methyl decyl, 4-methyl decyl, 5-methyl decyl, 6-methyl decyl, 7-methyl decyl, 8-methyl decyl, 9-methyl decyl, 1-methyl undecyl, 2-methyl undecyl, 3-methyl undecyl, 4-methyl undecyl, 5-methyl undecyl, 6-methyl undecyl, 7-methyl undecyl, 8-methyl undecyl, 9-methyl undecyl, 10-methyl undecyl, 1-ethyl propyl, 1-ethyl butyl, 2-ethyl butyl, 1-ethyl pentyl, 2-ethyl pentyl, 3-ethyl pentyl, 1-ethyl hexyl, 2-ethyl hexyl, 3-ethyl hexyl, 4-ethyl hexyl, 1-ethyl heptyl, 2-ethyl heptyl, 3-ethyl heptyl, 4-ethyl heptyl, 5-ethyl hep tyl, 1-ethyl octyl, 2-ethyl octyl, 3-ethyl octyl, 4-ethyl octyl, 5-ethyl octyl, 6-ethyl octyl, 1-ethyl nonyl, 2-ethyl nonyl, 3-ethyl nonyl, 4-ethyl nonyl, 5-ethyl nonyl, 6-ethyl nonyl, 7-ethyl nonyl, 1-ethyl decyl, 2-ethyl decyl, 3-ethyl decyl, 4-ethyl decyl, 5-ethyl decyl, 6-ethyl decyl, 7-ethyl decyl, 8-ethyl decyl, 1-propyl butyl, 1-propyl pentyl, 2-propyl pentyl, 1-propyl hexyl, 2-propyl hexyl, 3-propyl hexyl, 1-propyl heptyl, 2-propyl heptyl, 3-propyl heptyl, 4-propyl heptyl, 1-pro pyl octyl, 2-propyl octyl, 3-propyl octyl, 4-propyl octyl, 5-propyl octyl, 1-propyl nonyl, 2-propyl nonyl, 3-propyl nonyl, 4-propyl nonyl, 5-propyl nonyl, 6-propyl nonyl, 1-butyl pentyl, 1-butyl hexyl, 2-butyl hexyl, 1-butyl heptyl, 2-butyl heptyl, 3-butyl heptyl, 1-butyl octyl, 2-butyl octyl, 3-butyl octyl, 4-butyl octyl, 1-pentyl hexyl, 1-pentyl heptyl and 2-pentyl heptyl.
I n an embodiment, R5 and R6 are substituted, linear or branched C1A2 alkyl, wherein the sub stituents are selected from anime, hydroxy, alkoxy, ester and keto.
In an embodiment, unsubstituted or substituted C3-8 cycloal kyl is selected from cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, bicyc I o [2.2.1] heptyl and bicyclo[3.1.1]heptyl.
In an embodiment, substituted C3-8 cycloalkyl is cycloalkyl with one or more equal or different alkyl groups such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, n-pentyl, iso-pentyl, neo-pentyl etc. The representative examples of branched C3-C10 monocyclic and bicyclic cy cloalkyl include, but are not limited to, methyl cyclohexyl, dimethyl cyclohexyl etc.
In an embodiment, the melamine derivatives are selected from melamine cyanurate, mela mine polyphosphate, dimelamine phosphate, melamine pyrophosphate, melamine borate, melamine ammonium polyphosphate and melamine ammonium pyrophosphate.
In an embodiment, the N-alkoxy piperidines amine derivatives of formula (I) are selected from N,N',N,"-tris{2,4-bis[(l-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]-s-tri- azin-6-yl}-3,3'-ethylenedii mi nodi propylamine; N,N',N"-tris{2,4-bis[(l-cyclohexyloxy-2, 2,6,6- tetramethy I pi peridi n -4-yl) n -buty lam i no] -s-triazin-6-yl}-3,3'-ethylenedii mi nodi propylamine; N,N',N"'-tris{2,4-bis[(l-octyloxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]-s-triazin-6- yl}-3,3'-ethylenedii mi nodi propylamine; N,N',N"-tris{2,4-bis[(l-octyloxy-2,2,6,6-tetra- methyl pi perid in -4-yl) n -buty lam i no] -s-triazin-6-yl]-3,3'-ethylenedii mi nodi propylamine;
N,N',N'"-tris{2,4-bis[(l-methoxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]-s-triazin- 6-yl]-3,3'-ethylenedii mi nodi propylamine; and N,N',N"-tris{2,4-bis[(l-methoxy-2,2,6,6-tetra- methyl pi perid in -4-yl) n -buty lam i no] -s-triazin-6-yl]-3,3'-ethylenedii mi nodi propylamine.
In an embodiment, the at least one organic flame-retardant additive is present in the range of > 0.1 to < 15.0 % by weight, based on the overal l weight of the flame-retardant composi tion. I n another embodiment, the at least one organic flame-retardant additive is present in the range of > 0.5 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition. In still in an embodiment, the at least one organic flame-retardant additive is present in the range of > 1 to < 15 % by weight, based on the overall weight of the flame- retardant composition. In still in another embodiment, the at least one organic flame-retard- ant additive is present in the range of > 1 to < 12 % by weight, based on the overall weight of the flame-retardant composition.
In an embodiment, the at least one organic flame-retardant additive is melamine or its deriv atives.
In an embodiment, the at least one melamine or its derivatives has a particle size < 15 micron. I n an embodiment, the at least one melamine or its derivatives are present in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition. In another embodiment, the at least one melamine or its derivatives are present in the range of > 0.5 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition. In still an embodiment, the at least one melamine or its derivatives are present in the range of > 1.0 to < 15.0 % by weight, based on the overal l weight of the flame-retardant composi tion. In still in another embodiment, the at least one melamine or its derivatives are present in the range of > 1.0 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition. In yet in an embodiment, the at least one melamine or its derivatives are present in the range of > 1.0 to < 10.0 % by weight, based on the overall weight of the flame-retardant composition. In yet another embodiment, the at least one melamine or its derivatives are present in the range of > 1.0 to < 8.0 % by weight, based on the overall weight of the flame- retardant composition.
In an embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame- retardant composition. I n another embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition. In still in an embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to < 9.0 % by weight, based on the overall weight of the flame-retardant composition. In still in another embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to < 9.0 % by weight, based on the overall weight of the flame-retardant composition. In yet another embodiment, the at least one N-alkoxy piperidines amine deriva tive of formula (I) is present in the range of > 0.5 to < 8.0 % by weight, based on the overal l weight of the flame-retardant composition. Yet in another embodiment, the at least one N- alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to < 3.0 % by weight, based on the overall weight of the flame-retardant composition. In another em bodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to < 2.0 % by weight, based on the overal l weight of the flame-retardant composition.
I n an embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) and the at least one melamine derivative are present in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition. In another embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) and the at least one mela mine derivative are present in the range of > 0.5 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition. In still in an embodiment, the at least one N- alkoxy piperidines amine derivative of formula (I) and the at least one melamine derivative are present in the range of > 0.5 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition. In still in another embodiment, the at least one N-alkoxy piper idines amine derivative of formula (I) and the at least one melamine derivative are present in the range of > 0.5 to < 11.0 % by weight, based on the overall weight of the flame-retardant composition. In yet another embodiment, the at least one N-alkoxy piperidines amine deriva tive of formula (I) and the at least one melamine derivative are present in the range of > 0.5 to < 10.0 % by weight, based on the overall weight of the flame-retardant composition. Yet in another embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) and the at least one melamine derivative are present in the range of > 0.5 to < 9.0 % by weight, based on the overall weight of the flame-retardant composition.
In an embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to < 5.0 % by weight and the at least one melamine derivatives is present in the range of > 3.0 to < 12.0 % by weight, each based on the overall weight of the flame-retardant composition. Yet another embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to < 3.0 % by weight and the at least one melamine derivative is present in the range of > 5.0 to < 10.0 % by weight, each based on the overall weight of the flame-retardant composition. Still another embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to < 2.5 % by weight and the at least one melamine derivative is present in the range of > 6.0 to < 9.0 % by weight, each based on the overall weight of the flame-retardant com position. In still yet another embodiment, the at least one N-alkoxy piperidines amine deriva tive of formula (I) is present in the range of > 0.5 to < 2.0 % by weight and the at least one melamine derivative is present in the range of > 7.0 to < 9.0 % by weight, each based on the overall weight of the flame-retardant composition. In yet another particular embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.8 to < 1.5 % by weight and the at least one melamine derivative is present in the range of
> 7.5 to < 8.5 % by weight, each based on the overall weight of the flame-retardant compo sition. In still another embodiment, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in an amount of 1.0 % by weight and the at least one melamine derivative is present in an amount 8.0 % by weight, each based on the overall weight of the flame- retardant composition.
In an embodiment, at least one polyamide copolymer is present in the range of > 83.0 to < 96.9 % by weight, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.1 to < 5.0 % by weight and the at least one melamine derivative is present in the range of > 3.0 to < 12.0 % by weight, each based on the overall weight of the flame-retardant composition. In another embodiment, at least one polyamide copolymer is present in the range of > 87.0 to < 94.5 % by weight, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to < 3.0 % by weight and the at least one melamine derivative is present in the range of > 5.0 to < 10.0 % by weight, each based on the overall weight of the flame-retardant composition. In yet another embodiment, at least one polyamide copolymer is present in the range of > 88.0 to < 93.2 % by weight, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to < 2.5 % by weight and the at least one melamine derivative is present in the range of
> 6.0 to < 9.0 % by weight, each based on the overal l weight of the flame-retardant compo sition. In still another embodiment, at least one polyamide copolymer is present in the range of > 81.0 to < 92.2 % by weight, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.5 to < 2.0 % by weight and the at least one melamine derivative is present in the range of > 7.0 to < 9.0 % by weight, each based on the overall weight of the flame-retardant composition in yet another embodiment, at least one polyam ide copolymer is present in the range of > 90.0 to < 91.7 % by weight, the at least one N- alkoxy piperidines amine derivative of formula (I) is present in the range of > 0.8 to < 1.5 % by weight and the at least one melamine derivative is present in the range of > 7.5 to < 8.5 % by weight, each based on the overall weight of the flame-retardant composition. In still another embodiment , at least one polyamide copolymer is present in an amount of 91.0 % by weight, the at least one N-alkoxy piperidines amine derivative of formula (I) is present in an amount of 1.0 % by weight and the at least one melamine derivative is present in an amount of 8.0 % by weight, each based on the overall weight of the flame-retardant compo sition.
In an embodiment, the presently claimed invention is directed to a process for preparing a composition comprising the steps of:
a. mixing at least one polyamide copolymer in an amount the range of > 85.0 to < 99.9 % by weight, based on the overall weight of the flame-retardant composition; and at least one organic flame-retardant additive in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition to obtain a homogenous mix ture; and
b. extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets.
In another embodiment, the presently claimed invention is directed to a process for preparing a composition comprising the steps of:
a. mixing at least one polyamide copolymer in an amount the range of > 85.0 to < 99.9 % by weight, based on the overall weight of the flame-retardant composition; and at least one organic flame-retardant additive in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition to obtain a homogenous mix ture; and
b. extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets.
In yet another embodiment, the presently claimed invention is directed to a process for pre paring a composition comprising the steps of:
a. mixing at least one polyamide copolymer in an amount the range of > 85.0 to < 99.5 % by weight, based on the overall weight of the flame-retardant composition; and at least one organic flame-retardant additive in the range of > 0.5 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition to obtain a homogenous mix ture; and
b. extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets. In still an embodiment, the presently claimed invention is directed to a process for preparing a composition comprising the steps of:
a. mixing at least one polyamide copolymer in an amount the range of > 90.0 to < 99.5 % by weight, based on the overall weight of the flame-retardant composition; and at least one organic flame-retardant additive in the range of > 0.5 to < 10.0 % by weight, based on the overall weight of the flame-retardant composition to obtain a homogenous mix ture; and
b. extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets.
In still another embodiment, the presently claimed invention is directed to a process for pre paring a composition comprising the steps of:
a. mixing at least one polyamide copolymer in an amount the range of > 92.0 to < 99.5 % by weight, based on the overall weight of the flame-retardant composition; and at least one organic flame-retardant additive in the range of > 0.5 to < 8.0 % by weight, based on the overall weight of the flame-retardant composition to obtain a homogenous mix ture; and
b. extruding the homogenous mixture obtained in step a. to provide a solution comprising pellets.
In another embodiment, the at least one organic flame-retardant is dissolved in a solvent prior to mixing with at least one polyamide copolymer.
In another embodiment, the at least one melamine or its derivatives is dissolved in a solvent prior to mixing with at least one polyamide copolymer.
In an embodiment, the mixing in step a. is performed at a temperature in the range of > 20.0 to < 150.0 °C. I n another embodiment, the mixing step a. is performed at a temperature in the range of > 30.0 to < 150.0 °C. In yet another embodiment, the mixing step a. is performed at a temperature in the range of > 50.0 to < 150.0 °C. In still an embodiment, the mixing step a. is performed at a temperature in the range of > 80.0 to < 150.0 °C. Still in another embodi ment, the mixing step a. is performed at a temperature in the range of > 100.0 to < 150.0 °C.
I n an embodiment, the extrusion step b. is performed at a temperature in the range of > 20.0 to < 450.0 °C. I n another embodiment, the extrusion step b.is performed at a temperature in the range of > 100.0 to < 350.0 °C. In yet another embodiment, the extrusion step b. is per formed at a temperature in the range of > 150.0 to < 300.0 °C. In still an embodiment, the extrusion step b. is performed at a temperature in the range of > 180.0 to < 280.0 °C. in still in another embodiment, the extrusion step b. is performed at a temperature in the range of > 180.0 to < 250.0 °C.
In an embodiment, the presently claimed invention is directed to the use of the flame-retard- ant composition as described above for the preparation of multilayer polymer films, fibers or carpets In an embodiment, the presently claimed invention is directed to fibers made from the flame- retardant composition as defined above.
Within the context of the presently claimed invention, the term“fiber” refers to filamentous material that can be used in fabric and yarn as well as textile fabrication. One or more fibers can be used to produce a fabric or yarn. The yarn can be fully drawn or textured according to methods known in the art. I n an embodiment, the face fibers can include bulked continuous filament (BCF) or staple fibers for tufted or woven carpets.
Within the context of the presently claimed invention, the term“fibrous substrate” includes, but is not limited to, textiles, carpets, apparel, furniture coverings, drapes, upholstery, bed ding, automotive seat covers, and the like, that include fibers or yarns. In an embodiment, fibrous substrates can include air-craft fibrous substrates such as air-craft textiles, air-craft carpets, air-craft seat covering, and the like. It should be noted that embodiments of the present disclosure can include fibrous substrates that are non-woven fabrics or needle felt.
Within the context of the presently claimed invention, the term“carpet” may refer to a struc ture including face fiber and a backing. A primary backing may have a yarn tufted through the primary backing. The underside of the primary backing can include one or more layers of material (e.g., coating layer, a secondary backing, and the like) to cover the backstitches of the yarn. I n general, a tufted carpet includes a pile yarn, a primary backing, a lock coat, and a secondary backing. In general, a woven carpet includes a pile yarn, a warp, and weft skele ton onto which the pile yarn is woven, and a backing. Embodiments of the carpet can include woven, non-woven, and needle felts. A needle felt can include a backing with fibers attached as a non-woven sheet. A non-woven covering can include backing and a face side of different or similar materials.
I n an embodiment, the presently claimed invention is directed to a carpet comprising:
i) a pile yarn comprising the flame-retardant composition; and
ii) latex used for binding the pile yarn to the backing fabric.
In another embodiment, the presently claimed invention is directed to a carpet comprising: i) a pile yarn comprising the flame-retardant composition;
ii) a backing fabric containing polyester fiber; and
iii) latex used for binding the pile yarn to the backing fabric,
wherein the pile yarn comprising the flame-retardant composition having a limiting oxygen index of 26.0 or more; the backing fabric having a limiting oxygen index of 26.0 or more; and the latex having a limiting oxygen index of 26.0 or more.
In another embodiment, the backing fabric having the limiting oxygen index of 26.0 or more is formed by coating or impregnating the backing fabric containing polyester fiber with the latex having the limiting oxygen index of 26.0 or more and curing the latex. In an embodiment, the carpet according to presently claimed invention, wherein the backing fabric contains polyester fiber.
In an embodiment, the carpet according to presently claimed invention, wherein the flame- retardant composition of the pile yarn further contains a heat stabilizer.
I n an embodiment, the carpet according to presently claimed invention, wherein the at least one heat stabilizer is selected from at least one hindered phenolic compound and at least one hindered amine compounds.
In an embodiment, the at least one hindered phenolic compound and/or the at least one hindered amine compound are selected from N,N-hexamethylenebis(3,5-di-t-butyl-4-hydrox- yphenyl) propionate, 1,3-benzene dicarboxyamide and N,N' -bis(2,2,6,6-tetramethyl-4-pi- peridinyl).
I n an embodiment, the at least one heat stabilizer is present in the flame-retardant nylon in the range of 0.1 to 1.0% by weight, based on the total weight of the flame-retardant nylon.
In an embodiment, the carpet according to presently claimed invention, wherein the flame- retardant composition for the pile yarn contains at least one flow stability improver.
I n an embodiment, the at least one flow stability improver is a metal salt of a fatty acid.
I n an embodiment, the at least one flow stability improver is selected from magnesium stea rate, montanic acid magnesium, magnesium behenate, magnesium 12-hydroxystearate and calcium stearate, amide ethylene-bis-stearate and amide ethylene-bis-behenate.
I n an embodiment, the at least one flow stability improver is present in the flame-retardant nylon in the range of 0.1 to 1.0% by weight, based on the total weight of the flame-retardant nylon.
I n an embodiment, the latex having the limiting oxygen index of 26.0 or more is obtained by blending 30.0 to 200.0 parts by weight of expanded graphite and/or 10.0 to 100.0 parts by weight of at least one flame-retardant with 100.0 parts by weight of a latex component. In another embodiment, the at least one flame-retardant is phosphoric flame retardant.
In an embodiment, the carpet according to presently claimed invention, wherein the flame- retardant composition comprises at least one flow stability improver is selected from magne sium stearate, magnesium montanic acid, magnesium behenate, magnesium 12-hydroxys- tearate, calcium stearate, amide ethylene-bis-stearate and amide ethylene-bis-behenate.
In an embodiment, the presently claimed invention is directed to a method for manufacturing a carpet comprising the steps of: i) a tufting step of implanting piles of the yarn comprising the flame- retardant composition as described above;
ii) a binding step of coating or impregnating the backing fabric containing polyester fiber with the latex containing 30.0 to 200.0 parts by weight of expanded graphite and/or 10.0 to 100.0 weight parts by weight of a flame-retardant with respect to 100.0 parts by weight of a latex component; and
iii) a curing step of curing the latex with which the backing fabric containing polyester fiber is coated or impregnated.
In an embodiment, the presently claimed invention is directed to a method for manufacturing a carpet comprising the steps of:
i) a tufting step of implanting piles of the nylon pile yarn made of the flame-retardant composition as described above having a limiting oxygen index of 26.0 or more, in the backing fabric containing polyester fiber;
ii) a binding step of coating or impregnating the backing fabric containing polyester fiber with the latex containing 30.0 to 200.0 parts by weight of expanded graphite and/or 10.0 to 100.0 weight parts by weight of a flame-retardant with respect to 100.0 parts by weight of a latex component; and
iii) a curing step of curing the latex with which the backing fabric containing polyester fiber is coated or impregnated.
In an embodiment, the presently claimed invention is directed to a method for manufacturing a carpet comprising the steps of:
i) a tufting step of implanting piles of the nylon pile yarn made of flame-retardant com position as described above having a limiting oxygen index of 26 or more in the backing fabric containing polyester fiber;
ii) a binding step of coating or impregnating the backing fabric containing polyester fiber with the latex containing 30.0 to 200.0 parts by weight of expanded graphite and/or 10.0 to 100.0 weight parts by weight of a phosphoric flame-retardant with respect to 100 parts by weight of a latex component; and
iii) a curing step of curing the latex with which the backing fabric containing polyester fiber is coated or impregnated.
In an embodiment, the nylon pile yarn having a limiting oxygen index of 26.0 or more is pre pared from a flame-retardant composition as defined above.
According to the invention, in the flame-retardant nylon carpet, the pile yarn containing nylon has the limiting oxygen index of 26.0 or more, the backing fabric containing polyester fiber has the limiting oxygen index of 26.0 or more, and the latex for binding the pile yarn to the backing fabric has the limiting oxygen index of 26.0 or more. Since each of the materials composing the carpet has high flame retardance such that the limiting oxygen index is 26.0 or more as described above, the flame-retardant nylon carpet is fit to be used in a vessel, a vehicle, an aircraft, a movie theater, a theater, a welfare facility and a tall building and having high flame retardance is realized regardless of using a nylon BCF for the pile yarn. In an embodiment, the presently claimed invention is directed to a laminated multilayer pol ymer film comprising at least one layer comprising the flame-retardant composition as de fined above.
In another embodiment, the laminated multilayer polymer film, comprising
(i) at least one layer comprising the flame-retardant composition as defined above; and
(ii) at least one layer comprising at least one polymer.
In another embodiment, the laminated multilayer polymer film, comprising
(i) at least one layer comprising the flame-retardant composition as defined above;
(ii) at least one layer comprising at least one polymer; and/or
(iii) aluminum and/or tin metal.
Still another embodiment, the presently claimed invention is directed to a laminated multi layer polymer film comprising:
(i) at least one layer comprising the flame-retardant composition as defined above;
(ii) at least one layer comprising at least one polymer; and
(iii) aluminum and/or tin metal.
I n yet another embodiment, the presently claimed invention is directed to a laminated multi layer polymer film comprising:
(i) at least one layer comprising the flame-retardant composition;
(ii) at least one layer comprising at least one polymer; and
(iii) aluminum metal.
In an embodiment, the at least one polymer layer is made from a polymer selected from pol yolefins, poly(ethylene-vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene tereph- thalates, polyvinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and iono- mers.
In an embodiment, presently claimed invention is directed to a process for producing a lami nated multilayer polymer film, comprising the steps of
i) preparing at least two films,
ii) laminating the at least two films,
wherein one film in step i) comprises the flame-retardant composition as defined above; and the other film or films comprise at least one polymer selected from polyolefins, polyethylene- vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers.
In an embodiment, the films or polymer layers may be obtained by a film extrusion or co extrusion process, casting process, blowing process or a biaxially orientation process, usually in the course of an extrusion process. The biaxially orientation process, usually in the course of an extrusion process is preferred in case of polyethylene terephthalates, yielding so called biaxially oriented PET films (“boPET films”). In an embodiment, the preparation of films from a flame-retardant composition as defined above and/or the at least one further polymer (FP) of polyolefins, poly(ethylene-vinyl alco hols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers may include stretching or bi axial orientation.
I n another embodiment, the stretching is performed by any methods known to those skilled in the art.
I n another embodiment, the polymer film of the said polymers is stretched by guiding it over at least one roll, preferably a roll system, or by extending it widthwise. If said polymer film is obtained in the form of a tube, it is likewise possible that said polymer film is stretched by blowing air into the tube of the said polymer film and hence stretching the polymer film. It will be appreciated that combinations of the methods are also possible.
In another embodiment, the said polymer film is guided over at least one roll, preferably through a roll system, the polymer film is stretched in extrusion direction, i.e. lengthwise. If the said polymer film, by contrast, is extended widthwise, it is stretched at right angles to extrusion direction.
I n an embodiment, the said polymer film, for stretching, is guided over at least one roll, pref erably through a roll system, the polymer chains of the at least one polyamide copolymer comprising the flame-retardant as described above or at least one further polymer are aligned parallel to the direction in which stretching is performed. The stretched polymer film obtained is then uniaxially oriented. The stretched polymer film obtained is likewise uniaxially oriented when the said polymer film, for stretching, is extended widthwise. In that case too, the poly mer chains of the at least one polyamide copolymer comprising the flame-retardant as de scribed above and of at least one further polymer are aligned parallel to the direction in which stretching is performed.
In an embodiment, "uniaxially oriented” means that the polymer chains are aligned essentially in one direction
I n an embodiment, the said polymer film, for stretching, is guided over a roll system and ad ditionally extended widthwise, the polymer chains of the at least one polyamide copolymer comprising the flame-retardant as described above and of any at least one further polymer are aligned parallel to both directions in which stretching is performed. The stretched polymer film obtained is then biaxial ly oriented.
In an embodiment,“biaxial ly oriented” means that the polymer chains are aligned essentially in two different directions, preferably at right angles to one another. I n an embodiment, if the above-described processes for stretching the said polymer film are combined, the polymer film is thus obtained, for example, in tubular form and the polymer fil m is stretched by blowing air into the tube of the polymer fil m and simultaneously guided over rolls and likewise stretched; thus, the stretched polymer film (SP) obtained is biaxially oriented.
In an embodiment, the said polymer film is typically stretched at a temperature above the glass transition temperature (Tg) of the at least one copolyamide and below the melting tem perature (Tm of the at least one copolyamide. If the said polymer film is a multilayer film, it is also preferable that the polymer film is stretched at a temperature below the melting temper ature (Tj of the at least one further polymer, especially preferably at a temperature below the melting temperature of the at least one further polymer having the lowest melting tem perature.
In an embodiment, the layers of aluminum metal or tin metal in the laminated film are usually obtained by applying a rolled foil or sheet, of aluminum metal and/or tin metal
In an embodiment, within the context of the presently claimed invention the term“layer” in relation to laminated multilayer polymer containing film means either (i) a single layer, gen erally an extruded film, of the at least one copolyamide and/or a single layer, generally an extruded fil m, of the at least one further polymer and/or a single layer, generally in the form of a rolled foil or sheet, of aluminum and/or tin metal or (ii) more than one layers, generally co-extruded films, of the at least one copolyamide and/or more than one layers, generally co extruded fil ms, of the at least one further polymer and/or a more than one layers, generally in the form of a rolled foil or sheet, of aluminum metal and/or tin metal.
Laminating of films, generally polymer films, mostly thermoplastic polymer films, is well known in the art.
Lamination is usually understood as the bonding of substrates of large surface area, more particularly for the production of composite films using suitable lamination adhesives includ ing adhesive polymers which may be formulated with typical auxiliaries. In the process for producing composite films, at least two films are usually bonded with one another using a lamination adhesive.
In a suitable mode for producing the laminated film the lamination adhesive is usually applied to the large-surface-area substrates to be bonded such as films from a copolyamide as de fined herein and/or films of the at least one further polymer of polyolefins, poly(ethylene- vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers and/or aluminum metal and/or tin metal, preferably with an adhesive layer thickness of 0.1 to 20.0 g/m2, more preferably 1.0 to 7.0 g/m2, by means, for example, of knife coating, spreading, etc. Typical coating techniques may be employed, examples being roller coating, reverse roller coating, gravure roller coating, reverse gravure roller coating, brush coating, rod coating, spray coating, air brush coating, meniscus coating, curtain coating or dip coating. After a short time for the water of the dispersion or organic solvents of the lamination adhesives to evaporate (usually after 1 to 60 seconds), the coated substrate may then be laminated with a second substrate, the temperature can be, for example, 20.0 to 200.0 ° C, preferably 20.0 to 100.0 ° C, and the pressure can be, for example, 100.0 to 3000.0 kN/m2, preferably 300.0 to 2000.0 kN/m2.
The lamination adhesive may be employed as a one-component composition, i.e. without ad ditional crosslinking agents or as a two-component composition including at least one cross- linking agent such as for example isocyanate crosslinkers. At least one of the fil ms may be metalized or printed on the side that is coated with adhesive. The stated films and foils may be bonded with one another or with a foil or film of a different type - for example, polymer films with metal foils, different polymer films with one another, etc. The stated foils and films may also, for example, be printed with printing inks.
The lamination adhesives useful for the lamination process according to the invention are the ones known in the art and they are preferably non-tacky. Lamination adhesives are distin guished from pressure-sensitive adhesive in that they have no or only very low tack at room temperature and are applied with pressure and at elevated temperatures. The tack as meas ured as so called Loop Tack is preferably less than 1,7 N/25 mm (adhesive coating weight of 20.0 pm on a 12.0 pm PET-film, measured on steel at 20.0 ° C with a delamination speed of 300.0 mm/min).
The lamination adhesives useful for the lamination process according to the invention are for example based on adhesive polymers dissolved in organic solvents or in the form of aqueous dispersions comprising at least one adhesive polymer dispersed in aqueous medium. Pre ferred dispersion adhesives are aqueous dispersions of polyacrylates or aqueous dispersions of polyurethanes. The adhesive polymers of the lamination adhesives may be polymers ob tainable by radical polymerization of ethylenically unsaturated compounds (monomers) or may be polymers obtainable by polycondensation, such as polyurethanes, for example. Suit able adhesive polymers are more particularly poly(meth)acrylates, ethylene/vinyl acetate co polymer, polyurethanes, polyamide resins, saturated polyesters, polyolefins, styrene/butadi ene block copolymers, styrene/isoprene block copolymers, polyimides, PVC, and polyvinylpyr rolidone.
In an embodiment, the presently claimed invention is directed to the use of a laminated mul tilayer polymer film as packaging film.
In an embodiment, the laminated film of the invention can be used as tubular pouch packag ing, as laterally sealed pouch packaging, as thermoformed packaging, for closable pouches and/or as cushion packaging. Preferably in case the laminated film (P) contains aluminium metal, usually as at least one inner layer(s) of the laminated film (P), it is used as retortable packaging film. In an embodiment, the presently claimed invention is directed to a wire or a cable comprising a conductor coated with at least one layer comprising the flame-retardant composition as defined above. In another embodiment, the wire or cable comprising a conductor directly coated with a layer comprising the flame-retardant composition as defined above.
In an embodiment, the flame-retardant composition as described above for the wire or the cable further contains at least one heat stabilizer selected from at least one hindered phenolic compound and at least one hindered amine compounds.
In an embodiment, the at least one hindered phenolic compound and/or the at least one hindered amine compound is selected from, but not limited to, N,N-hexamethylenebis(3,5-di- t-butyl-4-hydroxyphenyl) propionate, 1,3-benzene dicarboxyamide, N,N' -bis(2,2,6,6-tetra- methyl-4-piperidinyl), pentaerythritol tetra kis(3- (3, 5-d i-tert-buty I -4- hydroxy phenyl) propio nate (Irganox 1010) and 2',3-bis [[3- [3,5-di-tert-butyl-4-hyd roxyphenyl] propionyl]] propion- ohydrazide (Irganox 1024 MD).
In an embodiment, the wire or the cable according to presently claimed invention, wherein the flame-retardant composition as described above forms a coating around the conductor.
I n an embodiment, the wire or the cable according presently claimed invention, wherein the conductor is a copper metal core.
In another embodiment, the copper metal core may have a size of 0.1 to 25.0 mm2.
I n an embodiment, the insulation layer is of a thickness in the range of > 0.2 to < 1.3 mm. In yet another embodiment, the insulation layer is of a thickness in the range of > 0.2 to < 1.0 mm. In still another embodiment the insulation layer is of a thickness in the range of > 0.2 to < 0.8 mm. I n another embodiment, the insulation layer is of a thickness in the range of > 0.2 to < 0.5 mm.
In an embodiment, the presently claimed invention is directed to a process of forming an insulation coating around the conducting wire or the cable.
In an embodiment, the flame-retardant composition as defined above is applied using any conventional coating techniques.
A typical procedure is to apply the composition by extruding a substantially uniform layer onto a metal conductor. The extrusion may be carried out using a single screw extruder at the desired line speeds. The curing of the coating is typically accomplished by passing the insu lated wire through a pressurized steam tube immediately following extrusion.
In an embodiment, the wire or the cable of the invention pass the ISO 6722 test either at 125.0 ° C, or 150.0 ° C. In another embodiment, the wire or the cable of the invention pass the ISO 6722 test at 125.0 ° C and 150.0 ° C. There are three categories of cable which can be subjected to the ISO test 6722: thick wall, thin wall or ultra-thin wall. They are categorised based on the insulation thickness in relation to the conductor diameter and size. The thinner the wal l, the more challenging it is to pass the ageing standard.
In an embodiment, the wire or the cable of the invention passes a heat ageing measured according to ISO 6722 (thin wall cables as above) at 125.0 ° C of at least 3000 hrs.
In an embodiment, the wire or the cable of the invention passes a heat ageing measured according to ISO 6722 (thin wall cables as above) at 150.0 ° C of at least 240 hrs.
I n the following, there is provided a list of embodiments to further illustrate the present dis closure without intending to limit the disclosure to the specific embodiments listed below.
Embodiments:
1. A flame-retardant composition comprising:
(A) at least one polyamide copolymer in an amount the range of > 85.0 to < 99.9 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least one organic flame-retardant additive in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 85.1 to <100 % by weight based on the overall weight of the flame-retardant composition,
wherein the at least one polyamide copolymer is a polymerization product of
(Al) 15.0 % to 84.0 % by weight of at least one lactam,
(A2) 16.0 % to 85.0 % by weight of a monomer mixture comprising the following com ponents:
(A2a)at least one C32-C40 dimer acid and
(A2b)at least one C4-C12 diamine,
wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2);
wherein the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
Figure imgf000040_0001
formula (I),
wherein R4 and R2 are independently selected from formula (la);
R3 and R4 are independently selected from H and formula (la);
Figure imgf000041_0002
R5 and R6 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
R7 and R8 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000041_0001
wherein
m is 1 to 10,
Rg and R10 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl; Rn and R12 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000042_0001
wherein n is a number from 2 to 14;
Figure imgf000042_0002
Figure imgf000043_0001
2. The flame-retardant composition according to embodiment 1, wherein the at least one organic flame-retardant additive (B) is present in an amount in the range of > 0.1 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition.
3. The flame-retardant composition according to embodiment 1 or 2 further comprises at least one organic flame-retardant (C) selected from melamine and melamine deriva tives.
4. The flame-retardant composition according to embodiment 3, wherein the melamine derivatives are selected from melamine cyanurate, melamine polyphosphate, dimelamine phosphate, melamine pyrophosphate, melamine borate, melamine ammo nium polyphosphate and melamine ammonium pyrophosphate.
5. The flame-retardant composition according to any of the embodiments 3 to 4, wherein organic flame-retardant (C) is present in an amount in the range of > 5.0 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of >90.1 to <100 % by weight based on the overall weight of the flame-retardant composition.
6. The flame-retardant composition according to any of the embodiments 1 to 5, wherein the N-alkoxy piperidines amine derivatives of formula (I) are selected from N,N',N'"- tris2,4-bis[(l-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]-s-triazin- 6-y I -3, 3'-ethylenedii mi nodi propylamine; N,N',N"-tris2,4-bis[(l-cyclohexyloxy-2,2,6,6- tetramethyl pi perid in -4-yl) n-butylami no] -s-triazin-6-yl -3, 3'-ethy lenedii mi nodi propyla mine; N,N',N"'-tris2,4-bis[(l-octyloxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]- s-triazi n -6-y I -3, 3'-ethy lenedii mi nodi propylamine; N,N',N"-tris2,4-bis[(l-octyloxy-
2, 2,6, 6-tetra methyl pi peridin-4-yl) n- buty lam i no] -s-triazin-6-y 1-3, 3'-ethy lenedii mi nodi propylamine; N,N',N'"-tris2,4-bis[(l-methoxy-2,2,6,6-tetramethylpiperidin-4-yl) n-bu- ty la mi no] -s-triazin -6-y I -3, 3'-ethy lenedii mi nodi propylamine; and N,N',N"-tris2,4-bis[(l- methoxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]-s-triazin-6-yl-3,3'-ethylene- diiminodipropylamine.
7. The flame-retardant composition according to any of the embodiments 1 to 6, wherein the component (Al) is selected from 3-aminopropanolactam, 4-aminobutanolactam, 5-aminopentanolactam, 6-aminohexanolactam, 7-aminoheptanolactam, 8-aminooc- tanolactam, 9-aminononanolactam, 10-aminodecanolactam, 11-aminoundecanolactam and 12-aminododecanolactam.
8. The flame-retardant composition according to any of the embodiments 1 to 7, wherein the component (A2) comprises in the range from 45.0 to 55.0 mol % of component (A2a) and in the range from 45.0 to 55.0 mol % of component (A2b), based in each case on the total molar amount of component (A2).
9. The flame-retardant composition according to any of the embodiments 1 to 8, wherein the component (A2a) is prepared proceeding from unsaturated fatty acids which are selected from unsaturated C16 fatty acids, unsaturated C18 fatty acids and unsaturated C20 fatty acids.
10. The flame-retardant composition according to any of the embodiments 1 to 9, wherein the component (A2b) is selected from tetramethylenediamine, pentamethylenediamine, hexamethylenediamine, decamethylenediamine and dodecamethylenediamine.
11. The flame-retardant composition according to any of the embodiments 1 to 10, wherein the at least one polyamide copolymer is a random copolymer. The flame-retardant composition according to any of the embodiments 1 to 11, wherein the component (Al) is 6-aminohexanolactam, the component (A2a) is C36 dimer acid and the component (A2b) is hexamethylenediamine. The flame-retardant composition according to any of the embodiments 1 to 12, wherein
(A) at least one polyamide copolymer (A) is present in an amount the range of > 85.0 to < 94.9 % by weight, based on the overall weight of the flame-retardant composi tion;
(B) at least one organic flame-retardant additive (B) is present in the range of > 0.1 to < 5.0 % by weight, based on the overal l weight of the flame-retardant composition; and
(C) at least one organic flame-retardant additive (C) is present in an amount in the range of > 5.0 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of >90.1 to <100 % by weight based on the overall weight of the flame-retardant composition. A process for preparing a composition according to any of the embodiments 1 to 13 comprising the steps of:
a. mixing at least one polyamide copolymer in an amount the range of > 85.0 to < 99.9 % by weight, based on the overall weight of the flame-retardant composition; and at least one organic flame-retardant additive in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition to obtain a homogenous mixture;
wherein the total amount of (A) and (B) is in the range of > 85.1 to <100 % by weight based on the overall weight of the flame-retardant composition, and
b. extruding the homogenous mixture obtained in step a. to provide a solution com prising pellets;
wherein the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
Figure imgf000045_0001
formula (I), wherein Rj and R2 are independently selected from formula (la);
R3 and R4 are independently selected from H and formula (la);
Figure imgf000046_0001
R5 and R6 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
R7 and R8 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000046_0002
wherein
m is 1 to 10,
Rg and R10 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
Rn and R12 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000047_0001
wherein n is a number from 2 to 14;
Figure imgf000047_0002
formula (V);
Figure imgf000048_0001
The process according to embodiment 14, wherein the at least one polyamide copoly mer is a polymerization product of
(Al) 15.0 % to 84.0 % by weight of at least one lactam,
(A2) 16.0 % to 85.0 % by weight of a monomer mixture comprising the following com- ponents:
(A2a)at least one C32-C40 dimer acid and
(A2b)at least one C4-C12 diamine,
wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2). 16. The process according to any of the embodiments 14 to 15 further comprises at least one organic flame-retardant (C) selected from melamine and melamine derivatives.
17. The process according to embodiment 16, wherein the melamine derivatives are se lected from melamine cyanurate, melamine polyphosphate, dimelamine phosphate, melamine pyrophosphate, melamine borate, melamine ammonium polyphosphate and melamine ammonium pyrophosphate.
18. The process according to any of the embodiments 16 to 17, wherein organic flame- retardant (C) is present in an amount in the range of > 5.0 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of > 90.1 to <100 % by weight based on the overall weight of the flame-retardant composition.
19. The process according to any of the embodiments 14 to 18, wherein in the step a. mixing is performed at a temperature in the range of > 20.0 to < 150.0 °C.
20. The process according to any of the embodiments 14 to 19, wherein
(A) at least one polyamide copolymer (A) is present in an amount the range of > 85.0 to < 94.9 % by weight, based on the overall weight of the flame-retardant composi tion;
(B) at least one organic flame-retardant additive (B) is present in the range of > 0.1 to < 5.0 % by weight, based on the overal l weight of the flame-retardant composition; and
(C) at least one organic flame-retardant additive (C) is present in an amount in the range of > 5.0 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of > 90.1 to <100 % by weight based on the overall weight of the flame-retardant composition.
21. The use of the flame-retardant composition according to any of the embodiments 1 to
13 or the flame-retardant composition prepared according to any of the embodiments
14 to 20 for the preparations of multilayer polymer films, fibers or carpets.
22. Fibers comprising the flame-retardant composition according to any of the embodi ments 1 to 13.
23. A carpet comprising:
i) a pile yarn comprising the flame-retardant composition according to any of the embodiments 1 to 13; and
ii) latex used for binding the pile yarn to the backing fabric.
24. The carpet according to embodiment 23, wherein the backing fabric contains polyester fiber. 25. The carpet according to any of the embodiments 23 to 24, wherein the pile yarn further contains a heat stabilizer.
26. The carpet according to embodiment 25, wherein the heat stabilizer is selected from hindered phenolic compounds and hindered amine compounds.
27. The carpet according to embodiment 23, wherein the pile yarn comprising the flame- retardant composition optionally contains at least one flow stability improver.
28. The carpet according to embodiment 27, wherein the at least one flow stability improver is selected from magnesium stearate, magnesium montanic acid, magnesium behenate, magnesium 12-hydroxystearate, calcium stearate, amide ethylene-bis-stearate and amide ethylene-bis-behenate.
29. Method for manufacturing a carpet according to any of the embodiments 23 to 28 com prising the steps of:
i) a tufting step of implanting piles of the yarn comprising the flame-retardant com position according to any of the embodiments 1 to 13;
ii) a binding step of coating or impregnating the backing fabric containing polyester fiber with the latex containing 30.0 to 200.0 parts by weight of expanded graphite and/or 10.0 to 100.0 weight parts by weight of a flame-retardant with respect to 100 parts by weight of a latex component; and
iii) a curing step of curing the latex with which the backing fabric containing polyester fiber is coated or impregnated.
30. A laminated multilayer polymer film comprising at least one layer comprising the flame- retardant composition according to any of the embodiments 1 to 13.
31. The laminated multilayer polymer film according to embodiment 30, further comprising
(i) at least one layer comprising at least one polymer; and/or
(ii) aluminum and/or tin metal.
32. The laminated multilayer polymer film according to embodiment 31, wherein the at least one polymer is selected from polyolefins, poly(ethylene-vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinylidene chlo rides, maleic anhydride-grafted polyolefins, polyesters and ionomers.
33. A process for producing a laminated multilayer polymer film according to any of the embodiments embodiment 30 or 32 comprising the steps of
i) preparing at least two films,
ii) laminating the at least two films,
wherein one film in step i) comprises the flame-retardant composition according to any of the embodiments 1 to 13; and the other film or films comprise at least one polymer selected from polyolefins, poly(eth- ylene-vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, poly- vinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers.
34. The use of a laminated multilayer polymer film according to any of the embodi ments 30 to 32 or according to embodiment 33 as packaging film.
35. A wire or cable comprising a conductor coated with at least one layer comprising the flame-retardant composition according to any of the embodiments 1 to 13.
36. A wire or cable comprising a conductor directly coated with a layer comprising the flame-retardant composition according to any of the embodiments 1 to 13.
While the presently claimed invention has been described in terms of its specific embodi ments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the presently claimed invention
Examples
The presently claimed invention is illustrated in detail by non-restrictive working examples which follow. More particularly, the test methods specified hereinafter are part of the general disclosure of the application and are not restricted to the specific working examples.
Methods and materials:
NOR 116: CAS 191680-81-6 commercially available and purchased from BASF under the trade name FLAM ESTAB NOR 116®.
Melapure MC: is a salt of melamine and cyanuric acid available from BASF under the trade name Melapure MC®.
Pripol® 1009: C36 hydrogenated dimer acid is commercially available from Croda.
The elongation at break is determined according to ASTM D882-10.
The tensile strength is determined according to ASTM D882-10.
The weight loss is determined according to NFPA-701.
Synthesis of the copolyamide:
932 kg of caprolactam (component (Al)), 323.2 kg of Pripol® 1009 from Croda (C36 dimer acid, hydrogenated, component (A2a)), 77.84 kg of 85% by weight hexamethylenediamine solution (component (A2b)) in water and 153 kg of water were mixed in a 1930 L tank and blanketed with nitrogen. The outside temperature of the tank was heated to 290° C and the mixture was stirred at this temperature for 11 hours. In the first 7 h the mixture was stirred at elevated pressure, in the next 4 hours under reduced pressure, during which water formed was distil led off. The copolyamide obtained was discharged from the tank, extruded and pelletized. The pellets of the copolyamide obtained were extracted with water at 95° C for 4 x 6 hours and then dried at 90° C to 140° C in a nitrogen stream for 10 hours. The copolyamide obtained had a viscosity number of 259 ml_/g, a glass transition temperature of 38 °C and a melting temperature of 188 °C. The proportion of polyamide 6.36 in the copolyamide, based on the total weight of the copolyamide, was 30.3% by weight; the density was 1.076 g/ml_. Table 1: The examples of flame-retardant copolyamide compositions
Figure imgf000052_0001
* out of scope
Process for the preparation of the examples 2 to 6: The examples 2-6 were prepared by blending the copolyamide and the flame-retardant component and extrusion.
Table 2: Pellet formation of the compositions
Figure imgf000052_0002
Examples 1 to 3: Screw speed 100 RPM; Feeder speed 125; pelletizer speed 10.
Examples 4 to 5: Screw speed 100 RPM; Feeder speed 200; pelletizer speed 8.
Table 3
Figure imgf000052_0003
n.d. not determined. * out of scope
Tensile strength and elongation at break for present invention is calculated as value given in percentage of example 1.
The tensile strength values above 70 % of the comparative example without flame-re tardant and elongation at break values above 80% of the comparative example without flame- retardant show acceptable mechanical properties.
It is evident from that the at least one polyamide copolymer comprising the at least one organic flame-retardant additive retains desirable mechanical properties while adding additional flame-retardant properties.

Claims

CLAI MS
1 A flame-retardant composition comprising:
(A) at least one polyamide copolymer in an amount the range of > 85.0 to < 99.9 % by weight, based on the overall weight of the flame-retardant composition; and
(B) at least one organic flame-retardant additive in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition; wherein the total amount of (A) and (B) is in the range of > 85.1 to <100 % by weight based on the overall weight of the flame-retardant composition,
wherein the at least one polyamide copolymer is a polymerization product of
(Al) 15.0 % to 84.0 % by weight of at least one lactam,
(A2) 16.0 % to 85.0 % by weight of a monomer mixture comprising the following com ponents:
(A2a)at least one C32-C40 dimer acid and
(A2b)at least one C4-C12 diamine,
wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2);
wherein the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
Figure imgf000054_0001
formula (I),
wherein R4 and R2 are independently selected from formula (la);
R3 and R4 are independently selected from H and formula (la);
Figure imgf000055_0002
R5 and R6 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
R7 and R8 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
wherein
Figure imgf000055_0001
m is 1 to 10,
Rg and R10 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
Rn and R12 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000056_0001
5 wherein n is a number from 2 to 14;
Figure imgf000056_0002
10 formula (V);
Figure imgf000057_0001
2 The flame-retardant composition according to claim 1, wherein the at least one organic flame-retardant additive (B) is present in an amount in the range of > 0.1 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition.
3. The flame-retardant composition according to claim 1 or 2 further comprises at least one organic flame-retardant (C) selected from melamine and melamine derivatives.
4. The flame-retardant composition according to claim 3, wherein the melamine deriva tives are selected from melamine cyanurate, melamine polyphosphate, dimelamine phosphate, melamine pyrophosphate, melamine borate, melamine ammonium poly phosphate and melamine ammonium pyrophosphate.
5. The flame-retardant composition according to any of the claims 3 to 4, wherein organic flame-retardant (C) is present in an amount in the range of > 5.0 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of >90.1 to <100 % by weight based on the overall weight of the flame-retardant composition.
6. The flame-retardant composition according to any of the claims 1 to 5, wherein the N- alkoxy piperidines amine derivatives of formula (I) are selected from N,N',N'"-tris2,4- bis[(l-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]-s-triazin-6-yl-
3, 3'-ethy lenedii mi nodi propylamine; N,N',N"-tris2,4-bis[(l-cyclohexyloxy-2,2,6,6-tetra- methyl pi perid i n-4-yl) n-butylami no] -s-triazin-6-yl-3,3'-ethylenedii mi nodi propylamine; N,N',N'"-tris2,4-bis[(l-octyloxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]-s-tria- zi n -6-y I -3, 3'-ethy lenedii mi nodi propylamine; N,N',N"-tris2,4-bis[(l-octyloxy-2,2,6,6-tet- ramethyl pi perid in -4-yl) n-butylami no] -s-triazin-6-yl -3, 3'-ethy lenedii mi nodi propyla mine; N,N',N'"-tris2,4-bis[(l-methoxy-2,2,6,6-tetramethylpiperidin-4-yl) n-butylamino]- s-triazi n -6-y I -3, 3'-ethy lenedii mi nodi propylamine; and N,N',N"-tris2,4-bis[(l-methoxy- 2, 2,6, 6-tetra methyl pi peridin-4-yl) n- buty lam i no] -s-triazin -6-y 1-3, 3'-ethy lenedii mi nodi propylamine.
7. The flame-retardant composition according to any of the claims 1 to 6, wherein the component (Al) is selected from 3-aminopropanolactam, 4-aminobutanolactam, 5-ami- nopentanolactam, 6-aminohexanolactam, 7-aminoheptanolactam, 8-aminooctanolac- tam, 9-aminononanolactam, 10-aminodecanolactam, 11-aminoundecanolactam and 12-aminododecanolactam.
8. The flame-retardant composition according to any of the claims 1 to 7, wherein the component (A2) comprises in the range from 45.0 to 55.0 mol % of component (A2a) and in the range from 45.0 to 55.0 mol % of component (A2b), based in each case on the total molar amount of component (A2).
9. The flame-retardant composition according to any of the claims 1 to 8, wherein the component (A2a) is prepared proceeding from unsaturated fatty acids which are se lected from unsaturated C16 fatty acids, unsaturated C18 fatty acids and unsaturated C20 fatty acids.
10. The flame-retardant composition according to any of the claims 1 to 9, wherein the component (A2b) is selected from tetramethylenediamine, pentamethylenediamine, hexamethylenediamine, decamethylenediamine and dodecamethylenediamine.
11. The flame-retardant composition according to any of the claims 1 to 10, wherein the at least one polyamide copolymer is a random copolymer.
12. The flame-retardant composition according to any of the claims 1 to 11, wherein the component (Al) is 6-aminohexanolactam, the component (A2a) is C36 dimer acid and the component (A2b) is hexamethylenediamine.
13. The flame-retardant composition according to any of the claims 1 to 12, wherein
(A) at least one polyamide copolymer (A) is present in an amount the range of > 85.0 to < 94.9 % by weight, based on the overal l weight of the flame-retardant composi tion;
(B) at least one organic flame-retardant additive (B) is present in the range of > 0.1 to < 5.0 % by weight, based on the overal l weight of the flame-retardant composition; and
(C) at least one organic flame-retardant additive (C) is present in an amount in the range of > 5.0 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of >90.1 to <100 % by weight based on the overall weight of the flame-retardant composition.
14. A process for preparing a composition according to any of the claims 1 to 13 comprising the steps of:
a. mixing at least one polyamide copolymer in an amount the range of > 85.0 to < 99.9 % by weight, based on the overall weight of the flame-retardant composition; and at least one organic flame-retardant additive in the range of > 0.1 to < 15.0 % by weight, based on the overall weight of the flame-retardant composition to obtain a homogenous mixture;
wherein the total amount of (A) and (B) is in the range of > 85.1 to <100 % by weight based on the overall weight of the flame-retardant composition, and
b. extruding the homogenous mixture obtained in step a. to provide a solution com prising pellets;
wherein the at least one organic flame-retardant additive (B) is selected from N-alkoxy piperidines amine derivatives of formula (I), compounds of formula (I I), compounds of formula (I II), compounds of formula (IV), compounds of formula (V), compounds of for mula (VI), compounds of formula (VI I) and compounds of formula (VII I),
Figure imgf000059_0001
formula (I),
wherein Rj and R2 are independently selected from formula (la);
R3 and R4 are independently selected from H and formula (la);
Figure imgf000060_0001
R5 and R6 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
R7 and R8 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000060_0002
wherein
m is 1 to 10,
Rg and R10 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl;
Rn and R12 are independently selected from unsubstituted or substituted, linear or branched C1A2 alkyl and unsubstituted or substituted C3-10 cycloalkyl,
Figure imgf000061_0001
formula (III) wherein n is a number f
Figure imgf000061_0002
formula (VI);
Figure imgf000062_0001
15. The process according to claim 14, wherein the at least one polyamide copolymer is a polymerization product of
(Al) 15.0 % to 84.0 % by weight of at least one lactam,
(A2) 16.0 % to 85.0 % by weight of a monomer mixture comprising the following com ponents:
(A2a)at least one C32-C40 dimer acid and
(A2b)at least one C4-C12 diamine,
wherein the percentages by weight of components (Al) and (A2) are each based on the sum total of the percentages by weight of components (Al) and (A2).
16. The process according to any of the claims 14 to 15 further comprises at least one organic flame-retardant (C) selected from melamine and melamine derivatives.
17. The process according to claim 16, wherein the melamine derivatives are selected from melamine cyanurate, melamine polyphosphate, dimelamine phosphate, melamine pyro phosphate, melamine borate, melamine ammonium polyphosphate and melamine am monium pyrophosphate.
18. The process according to any of the claims 16 to 17, wherein organic flame-retardant (C) is present in an amount in the range of > 5.0 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of > 90.1 to <100 % by weight based on the overall weight of the flame-retardant composition.
19. The process according to any of the claims 14 to 18, wherein in the step a. mixing is performed at a temperature in the range of > 20.0 to < 150.0 °C.
20. The process according to any of the claims 14 to 19, wherein
(A) at least one polyamide copolymer (A) is present in an amount the range of > 85.0 to < 94.9 % by weight, based on the overall weight of the flame-retardant composition;
(B) at least one organic flame-retardant additive (B) is present in the range of > 0.1 to < 5.0 % by weight, based on the overal l weight of the flame-retardant composition; and
(C) at least one organic flame-retardant additive (C) is present in an amount in the range of > 5.0 to < 12.0 % by weight, based on the overall weight of the flame-retardant composition, wherein the total amount of (A), (B) and (C) is in the range of > 90.1 to <100 % by weight based on the overall weight of the flame-retardant composition.
21. The use of the flame-retardant composition according to any of the claims 1 to 13 or the flame-retardant composition prepared according to any of the claims 14 to 20 for the preparations of multilayer polymer films, fibers or carpets.
22. Fibers comprising the flame-retardant composition according to any of the claims 1 to 13.
23. A carpet comprising:
i) a pile yarn comprising the flame-retardant composition according to any of the claims 1 to 13; and
ii) latex used for binding the pile yarn to the backing fabric.
24. The carpet according to claim 23, wherein the backing fabric contains polyester fiber.
25. The carpet according to any of the claims 23 to 24, wherein the pile yarn further contains a heat stabilizer.
26. The carpet according to any of the claims 23 to 25, wherein the heat stabilizer is se lected from hindered phenolic compounds and hindered amine compounds.
27. The carpet according to any of the claims 23 to 26, wherein the pile yarn comprising the flame-retardant composition optionally contains at least one flow stability improver.
28. The carpet according to any of the claims 23 to 27, wherein the at least one flow stability improver is selected from magnesium stearate, magnesium montanic acid, magnesium behenate, magnesium 12-hydroxystearate, calcium stearate, amide ethylene-bis-stea- rate and amide ethylene-bis-behenate.
29. Method for manufacturing a carpet according to any of the claims 23 to 28 comprising the steps of:
i) a tufting step of implanting piles of the yarn comprising the flame-retardant compo sition according to any of the claims 1 to 13;
ii) a binding step of coating or impregnating the backing fabric containing polyester fiber with the latex containing 30.0 to 200.0 parts by weight of expanded graphite and/or 10.0 to 100.0 weight parts by weight of a flame-retardant with respect to 100 parts by weight of a latex component; and
iii) a curing step of curing the latex with which the backing fabric containing polyester fiber is coated or impregnated.
30. A laminated multilayer polymer film comprising at least one layer comprising the flame- retardant composition according to any of the claims 1 to 13.
31. The laminated multilayer polymer film according to claim 30, further comprising
(i) at least one layer comprising at least one polymer; and/or
(ii) aluminum and/or tin metal.
32. The laminated multilayer polymer film according to any of the claims 30 to 31, wherein the at least one polymer is selected from polyolefins, poly(ethylene-vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, polyvinyli- dene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers.
33. A process for producing a laminated multilayer polymer film according to any of the claims claim 30 or 32 comprising the steps of
i) preparing at least two films,
ii) laminating the at least two films,
wherein one film in step i) comprises the flame-retardant composition according to any of the claims 1 to 13; and
the other film or films comprise at least one polymer selected from polyolefins, poly(eth- ylene-vinyl alcohols), poly(ethylene-vinyl acetates), polyethylene terephthalates, poly- vinylidene chlorides, maleic anhydride-grafted polyolefins, polyesters and ionomers.
34. The use of a laminated multilayer polymer film according to any of the claims 30 to 32 or according to claim 33 as packaging film.
35. A wire or cable comprising a conductor coated with at least one layer comprising the flame-retardant composition according to any of the claims 1 to 13.
36. A wire or cable comprising a conductor directly coated with a layer comprising the flame-retardant composition according to any of the claims 1 to 13.
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