Albemarle Corporation

Daniel A De Schryver

Jon S Reed

Arthur G Mack

Susan D Landry

Charles H Kolich

Meng-Sheng Ao

Donald E Balhoff

Billie B Dadgar

Homer C Lin

Douglas W Luther

Rajeev S Mathur

Samuel G Thomas, Jr

John Randall Chaya

Anteneh Z Worku

Jon Shannon Reed

This invention provides aqueous flame retardant dispersions comprising water, a brominated flame retardant containing aromatically-bound bromine, at least one dispersant, at least one wetting agent, and at least one thickener. The brominated flame retardant has an average particle size of about 20 μm or less. The flame retardant dispersion contains about 50 wt % or more of brominated polymeric flame retardant, based on the total weight of the dispersion. Also provided are coating compositions, processes for forming flame retardant dispersions, processes for forming coating compositions, and processes for applying the coating compositions to textile substrates.

Flame retardants for textile applications

A fiber or filament which is formed from ingredients comprising (a) at least one fiber-forming thermoplastic polymer, and (b) at least one polybrominated anionic styrenic polymer is provided. The polybrominated anionic styrenic polymer has a bromine content of at least about 50 wt %. When the fiber-forming thermoplastic polymer is a polyester, the polybrominated anionic styrenic polymer is present in a flame resistant or flame retardant amount. When the fiber-forming thermoplastic polymer is a polyamide, the polybrominated anionic styrenic polymer is at least about 2 wt % of the fiber or filament. When the fiber-forming thermoplastic polymer is a polyolefin, at least one synergist is present and the polybrominated anionic styrenic polymer is no more than about 15 wt % of the fiber or filament.

Flame retarded fibers and filaments and process of production therefor

A fiber or filament which is formed from ingredients comprising (a) at least one fiber-forming thermoplastic polymer and (b) at least one polybrominated anionic styrenic polymer is provided. The polybrominated anionic styrenic polymer has a bromine content of at least about 50 wt %, and a GPC weight average molecular weight in the range of about 5000 to about 40,000, or a GPC weight average molecular weight of at least about 600,000. When the fiber-forming thermoplastic polymer is a polyester, the polybrominated anionic styrenic polymer is present in a flame resistant or flame retardant amount. When the fiber-forming thermoplastic polymer is a polyamide, the polybrominated anionic styrenic polymer is at least about 2 wt % of the fiber or filament. When the fiber-forming thermoplastic polymer is a polyolefin, at least one synergist is present and the polybrominated anionic styrenic polymer is no more than about 15 wt % of the fiber or filament.

N,N&prime;-piperazinebis(neopentylglycol)phosphoramidate is used in combination with at least one co-additive which is (i) melamine, (ii) one or more melamine compounds or derivatives, or (iii) both of (i) and (ii) to provide effective flame retardancy in thermoplastic polymers. With polymers that tend to release trace amounts of acid under thermal processing conditions, a hydrotalcite is preferably included in the composition. In acid-sensitive polymers such as polyesters, the N,N&prime;-piperazinebis(neopentylglycol)phosphoramidate should be free or essentially free of acid species as determinable by use of nmr, mass spec, and/or HPLC.

Flame retardant polymer compositions

A polyalkylene terephthalate polymer, such as polyethylene terephthalate, polybutylene terephthalate, blends or copolymers thereof, and analogous polyester-type engineering thermoplastics, with which has been blended a flame retardant amount of brominated styrenic polymer, such as brominated polystyrene, that, prior to blending, is characterized by (a) containing less than 700 ppm Cl and having a TGA temperature for 1% weight loss of 340&deg; C. or higher; and/or (b) having an actual M,which is within about 20%, and preferably within about 10%, of its calculated theoretical M,, the theoretical M,being based upon the actual bromine content of the brominated styrenic polymer and the M,of the styrenic polymer reactant used to produce the brominated styrenic polymer; and/or (c) being essentially free of each of the following impurities: (1) ethylene dichloride, (2) bromodichloroethane, (3) dibromochloroethane, (4) dibromodichloroethane, and (5) tribrormochloroethane. These compositions most preferably also further comprise a reinforcing amount of glass fiber and/or a flame retardant synergist dispersed therein. It is now possible to provide polyalkylene terephthalate compositions that have a UL-94 rating of V-O using both {fraction (1/16)}-inch test specimens and {fraction (1/32)}-inch test specimens, and that have superior electrical resistance characteristics as reflected by a higher comparative tracking index and greater melt stability as determined by capillary rheometry.

Polymer compositions containing brominated polystyrenic resins

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Bonheiden, Belgium

Daniel A De Schryver