Title of Invention

FLAME-RETARDANT POLYAMIDE COMPOSITION

Abstract Abstract FLAME-RETARDANT POLYAMIDE COMPOSITION The present invention relates to a fireproof polyamide composition that can essentially be used for manufacturing moulded materials. The invention also relates to a polyamide-based composition containing melamine cyanate and a novolac resin. The composition is particularly useful for making moulded articles used in the field of electric or electronic connector technology, such as members of circuit-breakers, switches or connectors.
Full Text



flame retardants used are red phosphorus and
] ': '
haloq'enated compounds such as dibroinopheno.l,
W - g
p o 1 v b i" om o d i p h e n o 1 s, =i j ':> o 1 v b r ora o d i o h e n o x i d e s a n d
li :! " J
bromiinated polvstvrenes. In the last twentv years, a
i| 5 ^ "
new class of flame retardants has been found, namelv
■organonitrogen compounds belonging to the triazine
family, such as melamine or derivatives thereof, for
instance melamine cyanurate and more recently melamine
phosphates, polyphosphates and pyrophosphates.
The advantage of this! latter class of flame retardants
lies j m the fact that the cornpounds' concerned do not
contaiin any halogens or phosphorus. Specifically, flame
\ ij
retardants containing! halogens or red phosphorus mav
If '!
generate toxic gases 6r vapors during the combust ion of
the i[ polyamide composition, or even- during the
\\ j)
production of said composition. However, the amounts of
certa'in rnelamine-based compounds needed to obtain
il i
satisfactory flame retardancv are verv high, especiallv
jl !
for compositions containing reinforcing fillers in the
form|of fibers such as glass fibers, mineral fillers or heaty.stable organic \ fibers. The . cost of these compositions due to the large amounts of certain
melaiiiine-based compounds, especially melamine
\l
polyphosphates, makes their commercialization
)\ I
unattractive. Furthermore, this high concentration of
jl 'i
melamine compounds \ presents certain drawbacks,
especially during the manufacture of the composition, such! as the production of vapor of the melamine
compounds, or durind the production of the molded
W J ■ .
articles, such as blockage ■ of ventilation pipes and
If i
There is thus a need to prepare f lame-retardant
■I I!
polvarnide compositions based on melamine compounds that
*ll i
deposition m molds.

Slave

a relatively low [content of me1amine compound

M o r e r; it v si; no v o I a c r e s': i n i s k n o w r i t o r e d u c e t h e w a t e r uptake of polyamide compositions and thus to increase

the

dimensional stability

of

the

■esulting parts .

However,
3r
relative!;/ larqe amount of novolac res in
leads to a significant reduction of the mechanical properties. There is [[thus a need to prepare polyamide compositions which allov: the manufacture of molded partis that have qood dimensional stability wren a relatively low content of novolac resin.

Wit at)

is more, it appears that novolac resin leads to a

reduction of the if flame-retardancy properties of
I) -J
polyamide compositi'ions comprisinq " f laine-retardant
comrjounds . This is especially observed in the examples
\i r
of the experimental section hereinbelow.

Therie is ■ thus a need to prepare a flame-retardant
If *
polyamide composition that has low water uptake and
with qood
that allows the production ■ " of ' part:
dimensional stability, while at the same time avoiding

the

drawbacks mentioned previously.



The

Applicant has now found, entirely surprisingly,

of
mel pos
thai: a. polyamide composition comprising a low content
novolac resin and a relatively low content of amine cyanurate, i' a rnelamine derivative, makes it sible to obtain ^optimal results in terms of flame
retardancy and water? uptake. Contrary to what was known hitherto, novolac resin does not impair the flame-rebardancy properties of the polyamide composition ;omprising a rnelamine derivative,
:)

Thos Ann 1 leant

has

furthermore'

found,

entirely

3urp novo syne act

risirialv, that in the polvamide composition the lac resin and' the me 1 amine cyanurate act rgistically, whereas these two compounds usually in different manners as flame renardants.

Specifically, novolac resin is known to be an aqent

t hat-

participates in - the formation ot a carbon layer

(char) that isolates the polyamide matrix from the flame. In contrast, melamlne cyanurate is known to act on the controlled breaking of the polvamide chains, causing the formation of drops of molten polvamide
(dripping), which thus prevents propagation of the combustion.

The
pol
present invention thus relates to the use, in a amide matrix, ;of a combination of mefamine
cyarijurate and of novolac resin as, or in relation with, a flame retardaiit.

One
base-and
rel The
subject of the present invention is a polyamide-'d composition comprising at least: : from 0.1% to 15% by weight of melamine cyanurate;
f rom 0.1% to 5% by weight of novolac. resin; tive to the total weight of the composition.
polvaniide is chosen from the group comprising the
polyamides obtained by polycondensation of a linear dicarboxylie acid with a linear or cyclic diamine, such as PA 6.6, PA 6.10, PA 6.12, PA 12.12, PA 4.6 or MXD 6, or between' an arornafic dicarboxylic acid and a linear or '} aromatic diamine, such as polyterephthalamides,
poivisophthalamides, polyaramides, and polymers
obtained by polycondensation of an amino acid with itself, the amino -acid possibly being generated by
hw-nlniwHr- onenina of a lactam ring, for instance PA 6,

PA 7|, PA 11 and PA 12.
The
composition of the invention mav also comprise copojly amides derived especially from the above
polyarnides, or mixtures of these polyarnides or copolyamides.
The ' preferred polyarnides are polyhexarnethylene
adipamide, polycaprolactam or copolymers and mixtures
between polyhexarnethylene adipamide and
po1y c a p r o1a c t am.
Use is generally made of polyarnides whose molecular weights are suited to injection-molding processes,
although polyarnides ,;of. lower viscosity may also be used .
The polyamide matrix may especially be a polymer comprising star or H- macromolecuiar chains and, where
appropriate, linear ., macromolecuiar chains. Polymers
comprising such star or H macromolecuiar chains are
described, for example, in documents FR 2 7 4 3 0"?7,
if FR 2\ 719 730, US 5 959 069, EP 0 632 703, EP 0 632 057
and EP 0 3 32 14 9.
According to another particular variant of the invention, the polyamide matrix of the invention may be a polymer of statistical tree type, preferably a copolyamide having a statistical tree structure. These copolyamides of statistical tree structure and the process for obtaining them are especially described in document WO 9 9/03909. The matrix of the invention may also; be a composition comprisdng a linear thermoplastic polymer and a star, H and'/or tree thermoplastic polymer as described above. ; The matrix of the invention may

a 1 s c c ornp rise a h y p e r b r a n c h e d c o p o 1 y a m i d e of t h e t y p e d e s c r i bed i n d o c u m e n t W 0 0 0 / 6 8298. The c orn p o s i t i o n o i
the . invention may also comprise ■ any combination of linear, star, H or tree thermoplastic polymer and

hype

r b ranched c o p o 1 y a n i i d e a s d e s c r i 3 :■ e d a b o v e .

The
composition according to the invention may comprise
between 20'; and 80!:; by weight and preferentially between 50% and 70% -by weight of polyamide, relative to ■total weight of the composition.
;he

The

imposition according to the invention may also

novolac
r e s I n s
a r e
r e s i n .
Novolac
coinplrj.se
polyhydroxy compounds, for example products of condensation of phenolic compounds with aldehydes. Thesis condensation reactions are generally catalyzed

with

an acid.

The jphenolic compounds may be chosen, alone or as a
mixture, from phenol, cresol, xylenol, naphthol, and ir
alkylphenols, for instance butvlphenol, tert-
butvlphenol or isooctvlphenol; or any other substituted
phenol. The aldehyde most commonly used is
formaldehyde. However, other aldehydes mav be used,
If such as acetaldehyde, para-formaldehyde , buryiaidenyde,
crotcfnaldehyde and giyoxal.
The resins used advantageously have a higher molecular weight of between 50 0 and 300 0 g/mol and preferably between 300 and 2000 g/mol.

Cornme

rcial novolac resins that may especially be



mentioned include the commercial produe

Durez-' ,

Vulkaldur'-' and Rhenosin'--'.

'he 'composition according to the invention may compris
between 0.1'=
1!
the total v/eiqht
3)>:3 u>:" by weight of novolao r^sin, especially from 1:- to 4 :: by weight, particularly 1', 13't or 4 % by weight or proportions between these
t.o
of
values, relative oomppsiLion.
The composition of the invention may comprise from n. J. '.-t.o 15% by weiqht and preferentially from 5% to 12 ■ bv weight of melamine cyanurate, relative to the total
n
we ight of the compos i t ion.
The .composition may also comprise reinforcing fillers chosen especially from the group ' comprising qlass
fibers, and/or mineral fillers such as kaolin, talc or
Jf woll&stonite, or alternatively exfoliable fillers. The
if weight concentration of the reinf orcincr fillers is
.1 advan'taqeously between 1"; and 50% bv weiqht and
prefe'rably between 15% and 50% by weight relative to
the dotal weight of the composition. A mixture of a1ass
i
fibers and of mineral fillers, such as wollaston.ite, may e;specially be us.ed.
The compositions of the invention may also comprise anv¬il additive usually used, in poly amide- based _:ompositioiis

used

for

he manufacture of molded articles. Thus,

examples of additives that may be mentioned include

UV
stabilizers,
ieat
stabilizers,
antioxidants,
lubricants, pigments, colorants, plasticizers or impact
stren'gth modifiers. By' way of example, the antioxidants and heat stabilizers are, for example, alkali metal halides, copper halides, sterically hindered phenolic
compounds and aromatic amines.. The UV stabilizers are generallv benzotriazol.es, benzophenones or HALS.

T\'a

compositions may moreover comprise in ooiaoin,-! >'; j _,[,

o trier
compounds known for their f lame-ret.^r clan cv
l!
pivpcL'.ies, for instance compounds based. on red phosphorus, and alkaline-earth metal hydroxides such as magnesium hydroxide.
There is no limit to the .types of impact strength
mod if .ier. It is generally elastorneric oolymer.s J-hat- Mv
II " '■ ' ± ' ' "'
be used for this ourpose. Examples of suitable
elastomers are ethylene-acrylic ester-maleic anhydride,
et hyld he-propylene-ma leic anhydride, and EPDMs
(ethyl;ene-propylene-diene monomer) optionally with a
grafted maleic anhydride. The weight concentration of
elastomer is advantageous 1 v between 0.1:-> and Lr)'^
relative to the total weight, of the. composition.
The cjdmpos i t ion according to the invention i s most preferentially constituted of:
2 0% to 30% by weight of poly amide resin,
especially a polyarnide b6.66, and copolymers or mixtures
!' thereof; l[ Oil?, to 15% by weight of melamine cyanurate;
ol 1"£ to 5* by weight of novolac resin;
V't to bO'r. by weight of reinforcing fillers ;
optionally ddaiUv^.b '-iwicn L n.'in ■-u-- •. i J_ _■ ■_, [..
comprising heat stabilizers, UV stabilizers,
|i antioxidants, lubricants, pigments, colorants,
jf plasticizers and impact strength modifiers;
the weight percentages .'being expressed relative to the
total .weight of the composition.

the various constituents generally in a single* or twin-screw : extruder, at a temperature
The compositions of the invention are obtained by mixing
'screw
sufficient to maintain' the polyamide resin in molten

niirdi'mii. ijenei
ally, the mixture ojjtdiiitsO id ^>;I;.L u.jrr, i ±\,
the jcorm of rods that are chopped into pieces to form granules. The me1amine cyanurate and the novolac resin may he added together -or separately to the polyamide by-hot cjr cold blending.
The addition of the compounds and additives may be performed by adding these compounds to the polvairnde melt j in pure form or, in the form of a concentrated mixture in a resin, for instance a polyamide resin.

The granules obtained are used as starting material for
feeding processes for1 manufacturing molded articles, such 'as in ject ion-molding, extrusion or extrusion-blew
mo
IdiPm
g processes.
Thus, the composition of the invention is particularly suitable for the manufacture of articles used in the

field

of electrical or electronic connections such as

circuit breakers, switches, connectors or the like.

A specific language is used in the description so as zo facilitate the understanding of the principle of the invention. However,- it should be understood that no
_i_ _i. i 111 C ■!) L ..L Oil 'J 1 L 11 c S O 'J p e '-' 1 '- i' '■
_L 1 1 .'Cll
-:ii . J. ■; J.'-.'i
by the use of this specific language. Modifications,
improvements and enhancements may especially be envisioned by a person skilled in the technical field
concerned on the basis of his general knowledge.
The term "and/or" includes the meanings "and", "or" and also any other possible combination of words connected to thi
s term.

Other

details or advantages of the invention will

emerge more clearly in the light of the example* below,
whicri ere given purely as a guide.
EXPERIMENTAL SECTION
Various compositions were manufactured bv mixing polyamide with the various compounds. The mixing is performed in a twin-screw extruder at a temperature of 26U°C;. The mixture is extruded in the form of r-ods -i-o form granules by chopping these rods.
T h e rnfe t e r i a 1 s used a'r e :
i
- Polyamide: polyhexamethylene adipamide (PA 6.6) sold
under the trade name Technyl A 27 A 00 sold by the
company Rhodia
il
- Melamme cyanurate: MC 2 5 sold by the company Crba
- Novolac resin: Rhenosin11-1 PR 95 sold by the company
i
Rhein Chemie
- Wollastonite: 1015 sold by the company Nyco
- Molding additives: talc, colorants, aluminum stearate
Flame-retardant mixture F: aluminum diethyl II phospHinate and melamine polyphosphate ii
- Glass fibers: 99B fdiameter of 10 urn} sold by the
company Vetrotex.
The weiaht percentaae concentration of each compound
ii and tihe mechanical and f lame-retardancy properties of
each composition are indicated in the table below:








. An article obtained by molding or shaping composition as claimed in one of claims 1 to 5.


Documents:

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Patent Number 277958
Indian Patent Application Number 2488/CHENP/2009
PG Journal Number 51/2016
Publication Date 09-Dec-2016
Grant Date 07-Dec-2016
Date of Filing 01-May-2009
Name of Patentee RHODIA OPERATIONS
Applicant Address 40, RUE DE LA HAIE-COQ,F-93306 AUBERVILLIERS,
Inventors:
# Inventor's Name Inventor's Address
1 COUILLENS, XAVIER, 14 RUE DES CATALPAS, F-31170 TOURNEFEUILLE,
2 VERGELATI, CAROLL, LIEU-DIT VILLENEUVE F-38118 SAINTE BAUDILLE DE LA TOUR,
3 AMORESE, MICHELANGELO, VIA PRINCIPE EUGENIO NO.9 I-20155 MILANO,
PCT International Classification Number C08L 77/02
PCT International Application Number PCT/EP07/61881
PCT International Filing date 2007-11-05
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 609827 2006-11-10 France