Title of Invention

POLYPHOSPHATE DERIVATIVE OF A 1,3,5-TRIAZINE COMPOUND, A PROCESS FOR THE PRODUCTION THEREOF

Abstract

A polyphosphate derivative of a 1, 3, 5-triazine compound, preferably melamine polyphosphate, with a) an average condensation coefficient n (number average) > 20, b) with a pH-value of a 10% slurry of the polyphosphate derivative in water at 25°C of 5 or higher, c) a molar ratio of 1,3,5-triazine compound to phosphorus (M/P)≤1.1, and d) a decomposition temperature > 320° C, at which the loss of weight amounted to 2%, e) a solubility≤0.1 g/100 ml.

Full Text

Polyphosphate derivative of a 1,3,5-triazine compound, a process for the production thereof and use thereof WO 00/02869 discloses polyphosphate salts of 1,3,5-triazine compounds which have an average condensation coefficient (number average) of greater than 20 and a molar ratio of triazine compound such as melamine to phosphorus (M/P) > 1.1. The WO-specification also describes a two-stage process for the production of those salts by conversion of a 1,3,5-triazine compound with orthophosphoric acid into the corresponding orthophosphate salt as well as thermal treatment for conversion of the orthophosphate salt into a polyphosphate of the 1,3,5-triazine compound. In addition to the orthophosphates it is also possible to use pyrophosphates. The polyphosphate salts described in that publication are desirably to be used as flame-retardant agents. WO-specification WO 97/44377 describes a melamine polymetaphosphate of a solubility of 0.01 to 0.10 g/100 ml in water at 25°C, a pH-value of 2.5 to 4.5, in the form of a 10% aqueous slurry at 25°C and a melamine content of 1.0 to 1.1 mole per mole of phosphorus. That melamine polymetaphosphate is also obtained in a two-stage process in which in a first stage melamine, urea and an aqueous orthophosphoric acid solution are mixed together in such a ratio that the molar ratio of melamine to orthophosphoric acid is 1.0 to 1.5 and the molar ratio of urea to orthophosphoric acid is 0.1 to 1.5. The reaction is effected at a temperature of 0 to 140°C with the removal of water, a powder double salt of orthophosphoric acid, melamine and urea being obtained. In a second stage that is calcined at a temperature of 240 to 340°C and in that case affords melamine polymetaphosphates. That publication also refers to flame-retardant agents as the field of use for the melamine polymetaphosphates. WO 00/02869 refers to the disadvantage of the melamine polymetaphosphates in accordance with WO 97/44377 that the melamine polymetaphosphates produced in accordance with the process described therein are unsuitable for the use as flame-retardant agents in polymers, in particular in polyamides and polyesters which are typically processed at elevated temperatures. According to the information set out in WO 00/02869 those melamine polymetaphosphates have inadequate heat resistance, impact strength, tensile strength and breaking strength. There was therefore no reason for the man skilled in the art to find pointers in WO 97/44377 for example for improving the polyphosphate salts in accordance with WO 00/02869. European laid-open application No 1 386 942 discloses flame- retardant agents which include a phosphinate or diphosphinate together with a 1,3,5-triazine compound, which are intended to improve the effect over the individual substances. When using polyphosphate salts in accordance with WO 00/02869 as flame-retardant agents in plastic materials, in particular in glass fibre- reinforced polyamides, polyesters, such as polyethylene terephthalate and polybutylene terephthalate which are usually processed at relatively high temperatures (more specifically above 320°C), premature partial decomposition was also noted, which on the one hand lead to an attack by the decomposition products on the moulding tools used and which later when used for example as electrical insulating lacquers on copper wires lead to an attack on the latter. The object of the invention was therefore that of further improving the polyphosphate salts of 1,3,5-triazine compounds, which are known from WO 00/02869, so that they are heat-resistant even at processing temperatures above 320°C and for that purpose have a low level of water solubility and a low level of conductivity. Surprisingly that object was attained by the present invention, in respect of which information on page 2 and page 11 of WO 00/02869 is in part in conflict. The polyphosphate derivatives according to the invention of a 1,3,5-triazine compound, in particular melamine polyphosphate, with an average condensation coefficient n (number average) > 20 and a pH-value of a 10% aqueous slurry of the polyphosphate derivative at 25°C of 5 or higher are characterised in that they have a molar ratio of 1,3,5-triazine compound to phosphorus, M/P 320°C. Those polyphosphate derivatives can be used as flame-retardant agents in any plastic materials, preferably thermoplastic materials and thermosetting materials, in particular also in glass fibre-reinforced polyamides and polyesters which are processed at high temperatures. In consideration of the information in WO 00/02869 on pages 1 and 2 as well as page 11, lines 15 - 20, that result was not to be expected but rather the man skilled in the art had to reckon on the fact that, with a M/P pH-value of the melamine polyphosphate above 5 can be obtained and that the phosphate derivatives with such a low M/P are not suitable as a flame- retardant agent for plastic materials such as glass fibre-reinforced polyamides and polyesters, because of the excessively low level of heat resistance. Because of the surprising heat resistance of the polyphosphate derivatives according to the invention, there are no longer any limitations in terms of the use of melamine polyphosphates and corresponding triazine derivatives as flame-retardant agents in plastic materials, in particular thermoplastic materials. The series of plastic materials into which the polyphosphate derivatives according to the invention can be incorporated are to be found on pages 6 and 7 of WO 00/02869, and for that reason the content of those pages is hereby made the subject-matter of the present application. The polyphosphates of the invention can be reproduced in simplified form by the following general formula: wherein M denotes a 1,3,5-triazine compound and n denotes the average condensation coefficient. For high and medium condensation coefficients n the sum formula can be reduced to (MHP03)n. Therein M once again denotes the 1,3,5-triazine compound and n denotes the average condensation coefficient. 1,3,5-Triazine compounds which fall to be considered are for example 2,4,6-triamine-l,3,5-triazine (melamine) and its derivatives, condensation products such as melam, melem, melon, ammeline and ammelide but also 2-ureidomelamine, acetoguanamine, benzoguanamine and diaminophenyltriazine. It will be appreciated that it is also possible to use mixtures of those 1,3,5-triazine compounds. Melamine, its derivatives and condensation products are preferred in the present invention, in particular melamine. The average condensation coefficient n of the phosphates can be ascertained in accordance with known methods such as for example by means of NMR, J. Am. Chein. Soc. 78, 5715 (1956). The average condensation coefficient n is preferably at least 30, still more preferably in the range of 40 to 150. That average condensation coefficient can also be referred to as the average chain length of the phosphate derivative. The polyphosphate derivatives according to the invention have an enhanced heat resistance at 320° to 370°C. That is determined by the temperature at which the weight loss is 2%. The low M/P-ratio results in a higher P content and thus a process effect which is 15% better and an extremely low level of water solubility, which is of very great significance in terms of plastic products, in particular in the outdoor region. The water solubility of the polyphosphate derivatives according to the invention is preferably below 0.1 g/100 ml and still more preferably below 0.01 g/100 ml. With those orders of magnitude it is possible to refer to a product which is virtually insoluble in water. As mentioned the molar ratio M/P is preferably below 1.0 and still more preferably between 0.8 and 1.0. The pH-value is determined in a 10% aqueous slurry of the polyphosphate derivative according to the invention, by a procedure whereby 25g of the polyphosphate derivative and 225g of pure water are stirred at 25°C in a vessel and the pH-value of the resulting aqueous suspension is determined with conventional means. Preferred pH-values are approximately in the range of 5.1 to 6.9. Preferably the polyphosphate derivatives according to the invention have a decomposition temperature above 360, particularly above 380 and in particular above 400°C. A process according to the invention for the production of the polyphosphate derivatives set forth in claims 1 to 6 provides that an orthophosphate and/or at least one condensed phosphate of a 1,3,5- triazine compound, preferably melamine, with an average condensation coefficient n of below 20, is heat-treated in an ammonia atmosphere at a temperature in the range of 300 to 400°C, preferably in the range of 340 to 380°C, particularly preferably in the range of 370 to 380°C, and in that case a condensation product with an average condensation coefficient n (number average) > 20 is obtained. Usually the starting material involved is the melamine orthophosphate but that can be supplemented or replaced by condensed phosphates such as for example pyrophosphates and less condensed polyphosphates. The heat treatment must be effected for different periods of time at different temperatures depending on the respective starting phosphate used so that at any event the average condensation coefficient is above 20. The concentration of the ammonia in the gas atmosphere of the heat-treatment zone is desirably in the range of 0.1 to 100% by mass, preferably in the range of 1 to 30%, particularly in the range of 2 to 10%, in particular 3 to 5%. It is particularly desirable for the starting material used to be a 1,3,5-triazine compound, preferably a melamine compound, with a particle size which is as fine as possible, desirably an average particle size≤15 urn, preferably≤10 urn. With a coarser particle size grinding of the starting products is desirably effected prior to the heat treatment in order to produce the specified average particle sizes ≤ 15 µm, preferably ≤ 10 µrn. The flame-retardant properties of the polyphosphate derivatives according to the invention of a 1,3,5-triazine compound can be further increased if the polyphosphate derivatives are combined with at least one phosphinate and/or diphosphinate. Preferably the phosphinates or diphosphinates are of the following formulae I and II respectively: wherein R\ R2 are the same or different and CrCg-alkyl, straight or branched, C1- C7-hydroxyalkyl, straight or branched, or aryl, R3 is C1-C10-alkyls, straight or branched, C6-C10-aryls, alkylaryls or arylalkyls, M is Mg, Ca, Al, Sb, Sn, Ge, Ti, Zn, Fe, Zr, Ce, Bi, Sr, Mn, Li, Na, K and/or a protonised nitrogen base, preferably Ca, Mg, Al and Zn, m is 1 to 4, n is 1 to 4, and x is 1 - 4. Particularly preferably M is the same as Al. Desirably the flame- retardant mixtures contain so much of the polyphosphate derivative (A) according to the invention and the diphosphinate (B) that A:B = 3:7 to 7:3, preferably 3:4 to 4:3. The flame-retardant properties of the polyphosphate derivatives according to the invention of a 1,3,5-triazine compound can be quite particularly preferably also increased by the polyphosphate derivatives being mixed with aluminium phosphinates of the general formula (I): wherein R1 is -CH3, -CH2OH, -C2H5, -CH(OH)CH3 or -C(OH)(CH3)2, R2 is -CH2OH, -C2H4OH, -C3H6OH or -CH(OH)CH3, M is Al, and m 1 to 4 The aluminium phosphinate mixtures can be obtained by the free phosphinic acids being obtained in aqueous solution in known manner from alkali phosphinate mixtures and by their being reacted by subsequent boiling with aluminium hydroxide or aluminium oxyhydroxide slurries in water. It is found however that this neutralisation reaction takes up reaction times which are many times longer. It is therefore more appropriate for the alkali phosphinates obtained from the phosphorus reaction to be caused to react with the required amount of water-soluble aluminium salts such as for example chloride, hydroxychloride, sulphate, nitrate or formiate in aqueous solution, in which respect it may be necessary to completely dissolve the mixture by a small mineral acid addition and then to precipitate the aluminium phosphinate mixtures by raising the pH-value to 4 to 7. Subsequent heating of the aqueous suspension to temperatures between 105 and 150°C in pressure vessels facilitates later separation of the difficultly soluble precipitate. The aluminium phosphinate precipitate is then filtered, washed and dried. A further advantageous embodiment of the invention is characterised in that all or a part of the flame-retardant agents, that is to say the polyphosphinate derivative or derivatives and/or the phosphinate or phosphinates and/or diphosphinate or diphosphinates and/or the further included per se known flame-retardant agents, are coated with a silicon- bearing coating agent and/or modified in some other fashion. Such a modification is known for example from DE 198 30 128 Al, the content of which is hereby incorporated into the subject-matter of the present application by reference thereto. With the modification procedure an organofunctional silane or a mixture of organofunctional silanes or an oligomeric organosiloxane or a mixture of oligomeric organosiloxanes or a solvent-bearing preparation based on monomeric organosilanes and/or oligomeric organosiloxanes or a preparation based on water-soluble organopolysiloxanes are applied to a flame-retardant agent in powder form and the flame-retardant agent is kept in motion during the coating operation. Preferably 0.05 to 10% by weight of silicon-bearing coating agent with respect to the amount of flame-retardant agent is used. Desirably the coating agent is applied to the flame-retardant agent in the course of 10 seconds to 2 hours at a temperature of 0 to 200°C. It is further advantageous if the flame-retardant agent which is coated with coating agent is subjected to a post-treatment under the effect of heat at a temperature of up to 200°C and/or under reduced pressure. The organofunctional silane used is advantageously an aminoalkyl- or epoxyalkyl- or acryloxyalkyl- or methacryloxyalkyl- or mercaptoalkyl- or alkenyl- or alkyl-functional alkoxysilane. A particular advantage of modifying the flame-retardant agent with silicon-bearing coating agent is that the flame-retardant agent is more resistant to environmental influences such as moisture. The modification provides that washing-out of the flame-retardant agent in the course of time is prevented or reduced. The invention is further described by reference to the following Examples. Example 1 and Comparative Example 1 a. 876.96 kg of melamine was mixed in a blade mixer. 784 kg of 75% phosphoric acid was brought into contact with the melamine by spraying, in which case the reaction took place. The melamine orthophosphate formed was finely ground in an ACM-mill. b. The melamine orthophosphate was heat-treated in an oven. The oven temperature was set to 380°C before the melamine orthophosphate was introduced into the oven. The temperature and the ammonia concentration in the oven atmosphere were respectively set and kept approximately constant throughout the entire experiment. An ammonia atmosphere was created in the oven, with the ammonia concentration in the ammonia atmosphere being variable. In Example 1 in accordance with the invention a relatively high ammonia concentration, namely corresponding to -3 mm water column, was set. One result was that the pH-value was 5.524 and thus markedly above 5. At the same time the solubility at 0.032 g/100 ml was reduced to approximately a third in comparison with the subsequent Comparative Example. It was not possible to find any chemical attack on the moulding tools in the subsequent processing operation. The heat resistance of the product of Example 1 was about 373°C-TGA (2% weight loss), that is to say a weight loss of 2% was achieved at about 373°C. In Comparative Example 1 a lower ammonia concentration than in Example 1 was set by altering the level of ammonia concentration in the oven atmosphere. That corresponded to -100 mm water column. The effect was that the pH-value now abruptly fell and was about 3.57 in the suspension. The heat resistance was about 353°C-TGA (2% weight loss). The conditions and results of this experiment are set out in Table 1. In this case the heat resistance was practically the same in both tests, but the pH-value in Example 2 according to the invention is considerably higher than in the case of Comparative Example 2. WE CLAIM: 1. A polyphosphate derivative of a 1, 3, 5-triazine compound, preferably melamine polyphosphate, with a) an average condensation coefficient n (number average) > 20, b) with a pH-value of a 10% slurry of the polyphosphate derivative in water at 25°C of 5 or higher, c) a molar ratio of 1,3,5-triazine compound to phosphorus (M/P)≤1.1, and d) a decomposition temperature > 320° C, at which the loss of weight amounted to 2%, e) a solubility≤0.1 g/100 ml. 2. A polyphosphate derivative as claimed in claim 1, wherein e) it has a solubility≤0.01 g/100 ml. 3. A polyphosphate derivative as claimed in claim 1 or 2, wherein it has a molar ratio (c) of 1,3,5-triazine compound to phosphorus between 0.8 und 1.0. 4. A polyphosphate derivative as claimed in one of claims 1 to 3 wherein a 10% slurry of the polyphosphate derivative in water at 25° C (b) has a pH-value in the range of 5.1 to 6.9. 5. A polyphosphate derivative as claimed in one of claims 1 to 4, wherein a) its average condensation coefficient (number average) > 30, particularly from 40 to 150. 6. A polyphosphate derivative as claimed in one of claims 1 to 5 wherein d) its decomposition temperature is higher than 360°C, preferably higher than 380°C, particularly higher than 400° C. 7. A process for the production of a polyphosphate derivative of a 1, 3,5-triazine compound as claimed in one of claims 1 to 6, wherein an orthophosphate or a condensed phosphate of a 1,3,5-triazine compound with an average condensation coefficient n (number average) below 20 is heat-treated in an ammonia atmosphere at a temperature in the range of 300 to 400°C until the average condensation coefficient is above 20 and the molar ratio of 1,3,5- triazine compound to phosphorus (M/P) is below 1.1. 8. A process as claimed in claim 7 wherein the heat treatment is effected in a temperature range of 340 to 380, preferably 370 to 380°C. 9. A process as claimed in claim 7 or 8 wherein prior to the heat treatment the polyphosphate derivative is ground to an average particle size ≤15 µm, preferably 10 µm. 10. A process as claimed in one of claims 7 to 9 wherein the heat treatment is effected in an ammonia atmosphere which contains ammonia in a concentration of 0.1 to 100, preferably 1 to 30, particularly 2 to 10, in particular 3 to 5% by mass. 11. A flame-retardant agent including at least one polyphosphate derivative of a 1,3,5-triazine compound as claimed in one of claims 1 to 6. 12. A flame-retardant agent as claimed in claim 11 wherein it also contains other per se known flame-retardant agents. 13. A flame-retardant agent as claimed in one of claims 11 and 12 wherein it additionally contains at least one phosphinate and/or diphosphinate. 14 A flame-retardant agent as claimed in one of claims 11 to 13 wherein it contains phosphinate of the general formula I and/or diphosphinate of the general formula II: wherein R1, R2 are the same or different and C1-C6-alkyl, straight or branched, C1-C7- hydroxyalkyl, straight or branched, or aryl, R3 is C1-C10-alkyls, straight or branched, C6-C10-aryls, alkylaryls or arylalkyls, M is Mg, Ca, Al, Sb, Sn, Ge, Ti, Zn, Fe, Zr, Ce, Bi, Sr, Mn, Li, Na, K and/or a protonised nitrogen base, preferably Ca, Mg, Al and Zn, m is 1 to 4, n is 1 to 4, and x is 1 -4. 15. A flame-retardant agent as claimed in claim 14 wherein M = Al. \6, A flame-retardant agent as claimed in claim 14 wherein the phosphinate is a phosphinate of the general formula I: wherein R1 is -CH3, -CH2OH, -C2H5, -CH(OH)CH3 or -C(OH)(CH3)2, R2 is -CH2OH, -C2H4OH, -C3H6OH or -CH(OH)CH3. M is Al, and m 1 to 4 A flame-retardant agent as claimed in one of claims 11 to 16 wherein the polyphosphate derivative or derivatives and/or the phosphinate or phosphinates and/or diphosphinate or diphosphinates and/or the further included per se known flame-retardant agents are coated with a silicon-bearing coating agent and-or modified in some other fashion. A polyphosphate derivative of a 1, 3, 5-triazine compound, preferably melamine polyphosphate, with a) an average condensation coefficient n (number average) > 20, b) with a pH-value of a 10% slurry of the polyphosphate derivative in water at 25°C of 5 or higher, c) a molar ratio of 1,3,5-triazine compound to phosphorus (M/P)≤1.1, and d) a decomposition temperature > 320° C, at which the loss of weight amounted to 2%, e) a solubility≤0.1 g/100 ml.

Documents:

00982-kolnp-2007 correspondence-1.1.pdf

00982-kolnp-2007 form-26.pdf

00982-kolnp-2007 priority document.pdf

00982-kolnp-2007-correspondence-1.2.pdf

00982-kolnp-2007-international search authority repot-1.1.pdf

0982-kolnp-2007-abstract.pdf

0982-kolnp-2007-claims.pdf

0982-kolnp-2007-correspondence others.pdf

0982-kolnp-2007-description (complete).pdf

0982-kolnp-2007-form1.pdf

0982-kolnp-2007-form2.pdf

0982-kolnp-2007-form3.pdf

0982-kolnp-2007-form5.pdf

0982-kolnp-2007-international publication.pdf

0982-kolnp-2007-international search authority report.pdf

0982-kolnp-2007-pct others.pdf

0982-kolnp-2007-pct request form.pdf

982-KOLNP-2007-(06-02-2012)-CORRESPONDENCE.pdf

982-KOLNP-2007-(27-09-2011)-AMANDED CLAIMS.pdf

982-KOLNP-2007-(27-09-2011)-DESCRIPTION (COMPLETE).pdf

982-KOLNP-2007-(27-09-2011)-EXAMINATION REPORT REPLY RECEIVED.pdf

982-KOLNP-2007-(27-09-2011)-FORM 1.pdf

982-KOLNP-2007-(27-09-2011)-FORM 2.pdf

982-KOLNP-2007-(27-09-2011)-FORM 3.pdf

982-KOLNP-2007-(27-09-2011)-OTHERS.pdf

982-KOLNP-2007-(27-09-2011)-PETITION UNDER RULE 137.pdf

982-KOLNP-2007-CORRESPONDENCE.pdf

982-KOLNP-2007-EXAMINATION REPORT.pdf

982-KOLNP-2007-FORM 1.pdf

982-KOLNP-2007-FORM 18-1.1.pdf

982-kolnp-2007-form 18.pdf

982-KOLNP-2007-FORM 26.pdf

982-KOLNP-2007-FORM 3.pdf

982-KOLNP-2007-FORM 5.pdf

982-KOLNP-2007-GRANTED-ABSTRACT.pdf

982-KOLNP-2007-GRANTED-CLAIMS.pdf

982-KOLNP-2007-GRANTED-DESCRIPTION (COMPLETE).pdf

982-KOLNP-2007-GRANTED-FORM 1.pdf

982-KOLNP-2007-GRANTED-FORM 2.pdf

982-KOLNP-2007-GRANTED-SPECIFICATION.pdf

982-KOLNP-2007-REPLY TO EXAMINATION REPORT.pdf