Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
2000-12-21
2003-03-11
Szekely, Peter (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C523S200000, C523S205000, C523S351000, C524S100000, C524S101000, C524S126000, C524S127000, C524S128000, C524S140000, C524S141000, C524S145000, C524S147000, C524S153000
Reexamination Certificate
active
06531530
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a flame retardant resin composition having excellent impact resistance, heat resistance, dimensional stability and flame retardance in the resulting molded articles, a process for producing the composition and molded articles obtained from the composition.
PRIOR ART
Aromatic polyester resins are widely used as engineering plastics having excellent mechanical properties in the field of the appliance industry. However, although the resins are excellent in mechanical properties such as heat resistance, the resins are poor in dimensional stability of products produced by injection molding, having a problem in that use for members requiring dimensional accuracy is limited.
In order to solve this problem, a composition consisting of a polyester resin, an ABS resin, and an inorganic filler is proposed, for example, in JP-A 50-23448. However, since most plastics are flammable, in order to ensure a safety from flame, high flame retardance can be required, for example, which corresponds to V-0 in evaluation according to the vertical flammability test of the U.S. Underwriters' Laboratories (UL) Standard (Hereinafter referred to as UL94 Standard). Accordingly, a halogen flame retardant represented by bromine compounds and antimony oxide in general are blended with a thermoplastic resin to increase the flame retardance. However, there is probability that resins containing the halogen flame retardant may burn to generate dioxins, which may give a bad effect to the environment. Therefore, non-halogen, organic flame retardant resins have been strongly demanded as a recent tendency.
A flame retardant resin composition consisting of a vinyl copolymer, a polyester and/or a polyamide and a phosphorus flame retardant having a phosphorus content of 15% by weight or more is proposed, for example, in JP-A 10-298395. This composition is insufficient in heat resistance, represented by a heat deflection temperature, and in addition, a large amount of a flame retardant must be added in order to impart high flame retardance such as V-0 in UL-94. However, when red phosphorus exemplified in the Example is added in a large amount as a flame retardant, the red phosphorus itself burns in combustion so that conversely, the flame retardance decreases, which produces a problem in that there is a probability of generating a large amount of phosphine gas in fabrication.
DISCLOSURE OF THE INVENTION
An object of the invention is to provide a flame retardant resin composition having excellent capabilities such as impact resistance, heat resistance, dimensional stability and the like, and also having an excellent flame retardance in molded articles, a process for the preparation thereof, and molded articles obtained therefrom.
The invention, as a means for solution, provides a flame retardant resin composition comprising:
100 parts by weight of a thermoplastic resin (A) comprising:
80 to 10% by weight of (A-1) at least one of an aromatic polyester resin and a polyamide resin,
17 to 85% by weight of at least one of a rubber-containing copolymer of a vinyl cyanide and an aromatic vinyl (A-2) and a copolymer of a vinyl cyanide and an aromatic vinyl (A-3) and
3 to 40% by weight of (A-4) at least one of a polyphenylene ether resin and a polyphenylene sulfide resin,
1 to 60 parts by weight of a non-halogen, organic or inorganic flame retardant (B) and
100 parts by weight or less of a filler (C).
The present invention, as another means for solution, provides a process for producing the above-mentioned flame retardant resin composition, which comprises blending red phosphorus with at least one base resin selected from the aromatic polyester resin, the rubber-containing copolymer of a vinyl cyanide and an aromatic vinyl copolymer, the copolymer of a vinyl cyanide and an aromatic vinyl copolymer and the polyphenylene ether resin to obtain a masterbatch, and then melting and kneading the masterbatch with the other components.
The present invention further provides a molded article obtained by injection-molding the above-mentioned flame retardant resin composition.
DETAILED DESCRIPTION OF THE INVENTION
The aromatic polyester resins of component (A-1) of the invention are saturated polyester resins obtained according to known procedures through polycondensation of divalent or more carboxylic acids or the derivatives thereof having a capability to form esters with a dihydric or more alcohol component and/or phenol component or the derivatives thereof having a capability to form esters.
The aromatic polyester resins of component (A-1) include polyalkylene terephthalates such as polyethylene terephthalate, polybutylene terephthalate, and polyhexamethylene terephthalate etc., and polyalkylene naphthalates such as polyethylene naphthalate and polybutylene naphthalate, etc. In addition, component (A-1) can be copolyesters containing 50% by weight or more of alkylene arylate units or mixtures containing 50% by weight or more of alkylene arylate units in total. The aromatic polyester resins are preferably polyethylene terephthalate and polybutylene terephthalate because the resins are particularly excellent in balance of capabilities of molding properties, heat resistance, etc.
The molecular weight of the aromatic polyester resins of component (A-1) can be preferably selected from the range of about 10,000 to about 100,000 and more preferably about 15,000 to about 500,000 in weight average molecular weight.
The aromatic polyester resins of component (A-1) can be of a straight chain or branched chain structure, can be crosslinked, or can be used singly or in a combination of two or more thereof. It is desirable that in the aromatic polyester resins of component (A-1), particularly, use of a combination of polyethylene terephthalate and polybutylene terephthalate allows improvement in dimensional stability by the action of polybutylene terephthalate and improvement in appearance of the molded articles by the action of polyethylene terephthalate. The content ratio of these is preferably from 5/95 to 80/20 and more preferably from 10/90 to 50/50 in polyethylene terephthalate/polybutylene terephthalate.
The polyamide resins of component (A-1) include polyamide resins and the copolymers thereof formed from diamines and dicarboxylic acids; specifically, nylon 66, polyhexamethylene sebacamide (nylon 6·10), polyhexamethylene dodecanamide (nylon 6·12), polydodecamethylene dedecanamide (nylon 1212), polymethaxylylene adipamide (nylon MXD6), polytetramethylene adipamide (nylon 46), and the mixtures or copolymers of these; copolymers such as nylon 6/66, nylon 66/6T containing 50 mole % or less of component 6T (6T: polyhexamethylene terephthalamide), nylon 66/6I containing 50 mole % or less of component 6I (6I: polyhexamethylene isophthalamide), nylon 6T/6I/66, nylon 6T/6I/610 etc.; copolymers of polyhexamethylene terephthalamide (nylon 6T), polyhexamethylene isophthalamide (nylon 6I), poly(2-methylpentamethylene) terephthalamide (nylon M5T), poly(2-methylpentamethylene) isophthalamide (nylon M5I), nylon 6T/6I, nylon 6T/M5T etc., and moreover, copolymerized nylons such as amorphous nylon also can be used. Amorphous nylon includes a polycondensation product of terephthalic acid with trimethylhexamethylenediamine and the like.
Furthermore, the ring opening polymerization products of cyclic lactams, the polycondensation products of aminocarboxylic acids and copolymers consisting of these components, specifically aliphatic polyamide resins and the copolymers thereof such as nylon 6, poly-&ohgr;-undecanamide (nylon 11), poly-&ohgr;-dodecanamide (nylon 12) etc.; and polyamides consisting of diamines and dicarboxylic acids and the copolymers thereof, specifically nylon 6T/6, nylon 6T/11, nylon 6T/12, nylon 6T/6I/12, nylon 6T/6I/610/12 etc., and the mixtures of these are included.
The content ratio of component (A-1) contained in the compositions is from 80 to 10% by weight, preferably from 80 to 30% by weight, and more preferably from 75 to 35% by weight. The content ratio within this range can impa
Daicel Chemical Industries Ltd.
Flynn ,Thiel, Boutell & Tanis, P.C.
Szekely Peter
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