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WO 2015/087099 Al 18 June 2015 (18.06.2015) W P O P C T

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WO 2015/087099 Al 18 June 2015 (18.06.2015) W P O P C T (12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT) (19) World Intellectual Property Organization International Bureau (10) International Publication Number (43) International Publication Date WO 2015/087099 Al 18 June 2015 (18.06.2015) W P O P C T (51) International Patent Classification: AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY, C08L 77/02 (2006.01) C08K 5/3492 (2006.01) BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, C08L 77/06 (2006.01) C08K 5/5313 (2006.01) DO, DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT, C08K 3/32 (2006.01) C08L 23/08 (2006.01) HN, HR, HU, ID, IL, IN, IR, IS, JP, KE, KG, KN, KP, KR, KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD, ME, (21) International Application Number: MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO, NZ, PCT/IB20 13/00275 1 OM, PA, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW, SA, (22) International Filing Date: SC, SD, SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, 12 December 2013 (12. 12.2013) TN, TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW. (25) Filing Language: English (84) Designated States (unless otherwise indicated, for every (26) Publication Language: English kind of regional protection available): ARIPO (BW, GH, (71) Applicant: ITALMATCH CHEMICALS S.p.A. [IT/IT]; GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, SZ, TZ, UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU, TJ, Via Pietro Chiesa, 7/1 3 - Torri Piane, 1- 16149 San Benigno (Genova) (ΓΓ). TM), European (AL, AT, BE, BG, CH, CY, CZ, DE, DK, EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, ΓΓ, LT, LU, LV, (72) Inventor: ZUCCHELLI, Ugo; c/o Italmatch Chemicals MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM, S.p.A., Via Pietro Chiesa, 7/13, Torri Piane, 1-16149 San TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW, Benigno (Genova) (ΓΓ). KM, ML, MR, NE, SN, TD, TG). (74) Agent: TRUPIANO, Federica; Marietti, Gislon e Trupi- Published: ano S.r.L, Via Larga, 16, 1-20122 Milano (ΓΓ). — with international search report (Art. 21(3)) (81) Designated States (unless otherwise indicated, for every kind of national protection available): AE, AG, AL, AM, © (54) Title: HALOGEN-FREE FLAME RETARDANT POLYAMIDE MOULDING COMPOSITIONS WITH INCREASED GLOW ¾ WIRE AND FIRE RESISTANCE (57) Abstract: The present invention relates to halogen- free flame retardant compositions essentially comprising polyamide poly- mers (preferred is PA6), at least an Hypophosphorous acid metal salt (preferred is Aluminium hypophosphite), at least an organic phosphinate metal salt (preferred is Aluminium Di Ethyl Phosphinate), at least a Nitrogen based flame retardant agent (preferred is Melamine Cyanurate), at least an organic polyhydric polymer (preferred is EVOH) and optionally further conventional components. Such compositions are highly flame retarded at low thickness and have high Glow Wire temperature resistance. HALOGEN-FREE FLAME RETARDANT POLYAMIDE MOULDING COMPOSITIONS WITH INCREASED GLOW WIRE AND FIRE RESISTANCE BACKGROUND OF THE INVENTION The chemical composition of organic polymers make them easily combustible. Wide varieties of flame retardant additives are blend into polymers to achieve stringent standards demanded by processors and even by legislation. Recently, despite the fact that traditional brominated FR are well suited for most of application, some preference has been given to halogen free flame retardant additives because of environmental as well as for safety reasons. Consequently, halogen free flame retardant (FR) agents are of increasing interest in the thermoplastic polymers market. Basic requirements for these products are good processing characteristics in compounding and moulding conditions, good mechanical and electrical properties in the solid state, no blooming or discoloration, good flame retardant properties in both reinforced and unreinforced polymers. Particularly, flame retardant agents commonly used in Polyamides must satisfy stringent requirements concerning high processing temperatures, the absence of residual acidity that could cause polymer hydrolysis and the avoidance of blooming effects. These various requirements have limited the use of most of the known halogen free additives, apart from Red Phosphorus, Organic phosphinates and Hypophosphites (also called Hypophosphorus acid metal salts or inorganic Phosphinates ). Red phosphorus is the most effective flame retardant additive, especially for glass fiber reinforced polyamide, but its inherent red colour makes the corresponding polymer product difficult to be used for very light colours applications. Organic phosphinates metal salts have the following chemical Formula (I): p — o / FORMULA (I) where: "d" is an integer number ranging from 1 to 4 in dependence of the valence of the metal M. Metal M is any element belonging to groups I, II, III and IV of the periodic table of the elements. Preferred metals are selected as Aluminum, Zinc, and Calcium. R 1 and R9 are identical or different and are selected as hydrogen, C C -alkyl, linear or branched, aryl, provided that R and R be never selected as Hydrogen at the same time. 1 9 In other words, when R =H, R must be C -C6-alkyl, linear or branched, aryl. When, 1 on the other hand, R =H, R must be CrC 6-alkyl, linear or branched, aryl. When one of R 1 or 9 are hydrogen, resulting compounds of Formula (I) are called mono-alkyl-phosphinates. This family of organic phosphinates metal salts was described as flame retardant agents for example in EP 699708 and EP 6568. Organic phosphinates metal salts are particularly efficient in polyamides, especially when used in conjunction with a melamine containing product, the resulting mixture being more effective than organic phosphinates alone. These products, with particular regard to zinc and especially aluminium diethyl phosphinate, are currently commercially available under the "Exolit OP" brand, Clariant. Different processes for the preparation of Organic phosphinates metal salts were described, for instance in: CA 2641 112, US 6300516, US 5973194, US 601 172, DE 19910232, US 6090968, EP 1016623, US 6329544, US 6355832, US 6359171, US 6278012, US 2003073865, US 2002079480, US 2006074157, US 2005137418. Combinations of organic Phosphinates metal salts and condensation products of melamine and/or reaction products of melamine with phosphoric acid in polyamides and other thermoplastic polymers are described for example in US 655371, US 2004/0227130 , US 2005/0137300, US 2005/0234161, US 2006/0084734, US 2007/0072967, US 2008/0161490. Hypophosphites (also called Hypophosphorus acid metal salts or inorganic Phosphinates) have been reported as effective halogen free flame retardant additives for polymers. Hypophosphites are compounds of Formula (I) wherein R and R are selected as Hydrogen and "d" is an integer number ranging from 1 to 4 in dependence of the valence of the metal M. The metal is any element belonging to the groups I, II, III and IV of the periodic table of the elements. Preferred metals are Aluminium and Calcium. Sodium and calcium Hypophosphites are currently widely commercially available and they are normally produced by reacting the corresponding metal hydroxide on yellow phosphorus, for instance according to the following reaction scheme: P + 2Ca(OH)2 + H20 Ca(H2P0 2)2 + CaHP0 + PH3 Hypophosphites of metals other than Calcium and Sodium are normally produced through the hypophosphorus acid reaction on the metal hydroxide or by exchange reaction with the corresponding soluble metal salts (see for instance "Hypophosphorus Acid and its salts", Russian Chemical Review, 44 (12), 1975). Thermoplastic polyamides moulding materials containing Hypophosphites as flame retardant agents, were described, for instance in WO 09/010812, WO 2005/075566 and WO 2013/045966 According to WO 09/010812, a polymer composition, particularly based on polyesters or polyamides and comprising hypophosphites coated with inorganic hydrates and/or organic salts, is described. According to WO 2005/075566, a polyamide is made flame retardant by the addition of at least Aluminium Hypophosphite in the range of 1% to 30% by weight. According to WO 2013/045966, a polyamide is made flame retardant by the addition of at least an hypophosphorus acid metal salt (preferred is Aluminium hypophosphite), at least a nitrogen flame retardant agent, at least an organic polyhydric compound. OBJECT OF THE INVENTION Object of the present invention is to provide halogen-free highly flame retardant polyamides, unreinforced or reinforced. In the purpose of the present invention, the term "highly flame retardant" means ranking V0 classification on thin items, according to international standard UL-94. Thin items means thickness preferably lower than about 0,8 mm, and more preferably equal to 0,6 mm or even lower. Another object of present invention is to provide halogen free flame retardant polyamides with high Glow Wire resistance, particularly passing the GWIT test at higher than 800°C, according to IEC 61335-1. Another object of present invention is to provide halogen free flame retardant moulding compositions and articles based on polyamides with good electrical properties, good mechanicals and weathering resistance. DESCRIPTION OF THE INVENTION These and other objects according to the present invention are achieved by a polymer composition consisting of: a) at least a thermoplastic polyamide polymer, b) at least an Hypophosphite (also called Hypophosphorus acid metal salt or inorganic Phosphinate) as a first flame retardant ( 1st FR component) c) at least an Organic phosphinate metal salt as a second flame retardant (2nd FR component) d) at least a nitrogen based flame retardant agent as a third flame retardant (3rd FR component) e) at least an organic polyhydric polymer, as a fourth flame retardant (4th FR component) f) fillers and /or reinforcing fibers g) other conventional additives. The total percentage of components a) to g) must be 100%. The above percentage value is expressed in either weight or volume, preferably in weight.
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