JP4673626B2 - 難燃性樹脂組成物 - Google Patents
難燃性樹脂組成物 Download PDFInfo
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- JP4673626B2 JP4673626B2 JP2004564507A JP2004564507A JP4673626B2 JP 4673626 B2 JP4673626 B2 JP 4673626B2 JP 2004564507 A JP2004564507 A JP 2004564507A JP 2004564507 A JP2004564507 A JP 2004564507A JP 4673626 B2 JP4673626 B2 JP 4673626B2
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- Prior art keywords
- acid
- group
- compound
- resin
- aromatic
- Prior art date
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- 239000003063 flame retardant Substances 0.000 title claims description 107
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 title claims description 95
- 239000011342 resin composition Substances 0.000 title claims description 49
- -1 phosphorus compound Chemical class 0.000 claims description 511
- 229920005989 resin Polymers 0.000 claims description 268
- 239000011347 resin Substances 0.000 claims description 268
- 125000003118 aryl group Chemical group 0.000 claims description 132
- 150000003839 salts Chemical class 0.000 claims description 123
- 150000001875 compounds Chemical class 0.000 claims description 108
- 229910052751 metal Inorganic materials 0.000 claims description 103
- 239000002184 metal Substances 0.000 claims description 103
- 125000000217 alkyl group Chemical group 0.000 claims description 86
- 229910052698 phosphorus Inorganic materials 0.000 claims description 85
- 239000011574 phosphorus Substances 0.000 claims description 75
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 73
- 125000003277 amino group Chemical group 0.000 claims description 67
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 64
- 150000002903 organophosphorus compounds Chemical class 0.000 claims description 62
- 229910052757 nitrogen Inorganic materials 0.000 claims description 61
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 claims description 48
- 229920000642 polymer Polymers 0.000 claims description 47
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 42
- 229910019142 PO4 Inorganic materials 0.000 claims description 37
- 238000000034 method Methods 0.000 claims description 35
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- 125000002947 alkylene group Chemical group 0.000 claims description 26
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- 239000000945 filler Substances 0.000 claims description 25
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- 239000004721 Polyphenylene oxide Substances 0.000 claims description 20
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- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 claims description 17
- QQOWHRYOXYEMTL-UHFFFAOYSA-N triazin-4-amine Chemical class N=C1C=CN=NN1 QQOWHRYOXYEMTL-UHFFFAOYSA-N 0.000 claims description 17
- 125000003545 alkoxy group Chemical group 0.000 claims description 16
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 claims description 16
- BTBUEUYNUDRHOZ-UHFFFAOYSA-N Borate Chemical compound [O-]B([O-])[O-] BTBUEUYNUDRHOZ-UHFFFAOYSA-N 0.000 claims description 15
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- 229920003233 aromatic nylon Polymers 0.000 claims description 15
- 229920000069 polyphenylene sulfide Polymers 0.000 claims description 15
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 14
- 125000005499 phosphonyl group Chemical group 0.000 claims description 14
- 125000004437 phosphorous atom Chemical group 0.000 claims description 14
- 239000003381 stabilizer Substances 0.000 claims description 14
- 239000011593 sulfur Substances 0.000 claims description 14
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- 125000005375 organosiloxane group Chemical group 0.000 claims description 5
- 125000002029 aromatic hydrocarbon group Chemical group 0.000 claims description 4
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 claims description 4
- NMYFVWYGKGVPIW-UHFFFAOYSA-N 3,7-dioxabicyclo[7.2.2]trideca-1(11),9,12-triene-2,8-dione Chemical compound O=C1OCCCOC(=O)C2=CC=C1C=C2 NMYFVWYGKGVPIW-UHFFFAOYSA-N 0.000 claims description 3
- WSQZNZLOZXSBHA-UHFFFAOYSA-N 3,8-dioxabicyclo[8.2.2]tetradeca-1(12),10,13-triene-2,9-dione Chemical compound O=C1OCCCCOC(=O)C2=CC=C1C=C2 WSQZNZLOZXSBHA-UHFFFAOYSA-N 0.000 claims description 3
- 150000003973 alkyl amines Chemical class 0.000 claims description 3
- 230000007246 mechanism Effects 0.000 claims description 3
- PTMHPRAIXMAOOB-UHFFFAOYSA-L phosphoramidate Chemical compound NP([O-])([O-])=O PTMHPRAIXMAOOB-UHFFFAOYSA-L 0.000 claims description 3
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- LLLVZDVNHNWSDS-UHFFFAOYSA-N 4-methylidene-3,5-dioxabicyclo[5.2.2]undeca-1(9),7,10-triene-2,6-dione Chemical compound C1(C2=CC=C(C(=O)OC(=C)O1)C=C2)=O LLLVZDVNHNWSDS-UHFFFAOYSA-N 0.000 claims description 2
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- 125000005402 stannate group Chemical group 0.000 claims 1
- 239000002253 acid Substances 0.000 description 137
- UHOVQNZJYSORNB-UHFFFAOYSA-N monobenzene Natural products C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 119
- NBIIXXVUZAFLBC-UHFFFAOYSA-N phosphoric acid Substances OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 88
- 235000011007 phosphoric acid Nutrition 0.000 description 52
- 229920003986 novolac Polymers 0.000 description 51
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 46
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 43
- 229920000877 Melamine resin Polymers 0.000 description 42
- 239000002585 base Substances 0.000 description 42
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical class C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 39
- 239000000178 monomer Substances 0.000 description 36
- 235000021317 phosphate Nutrition 0.000 description 36
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 35
- 125000001997 phenyl group Chemical class [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 35
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 34
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 34
- 229920001577 copolymer Polymers 0.000 description 34
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 33
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 32
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 30
- QIGBRXMKCJKVMJ-UHFFFAOYSA-N Hydroquinone Chemical compound OC1=CC=C(O)C=C1 QIGBRXMKCJKVMJ-UHFFFAOYSA-N 0.000 description 28
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- 125000001931 aliphatic group Chemical group 0.000 description 25
- 125000003710 aryl alkyl group Chemical group 0.000 description 25
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- YZEZMSPGIPTEBA-UHFFFAOYSA-N 2-n-(4,6-diamino-1,3,5-triazin-2-yl)-1,3,5-triazine-2,4,6-triamine Chemical compound NC1=NC(N)=NC(NC=2N=C(N)N=C(N)N=2)=N1 YZEZMSPGIPTEBA-UHFFFAOYSA-N 0.000 description 20
- 235000010338 boric acid Nutrition 0.000 description 20
- GHMLBKRAJCXXBS-UHFFFAOYSA-N resorcinol Chemical compound OC1=CC=CC(O)=C1 GHMLBKRAJCXXBS-UHFFFAOYSA-N 0.000 description 20
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- 125000000623 heterocyclic group Chemical group 0.000 description 19
- ZFSLODLOARCGLH-UHFFFAOYSA-N isocyanuric acid Chemical compound OC1=NC(O)=NC(O)=N1 ZFSLODLOARCGLH-UHFFFAOYSA-N 0.000 description 19
- 125000004433 nitrogen atom Chemical group N* 0.000 description 19
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 18
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- YSRVJVDFHZYRPA-UHFFFAOYSA-N melem Chemical compound NC1=NC(N23)=NC(N)=NC2=NC(N)=NC3=N1 YSRVJVDFHZYRPA-UHFFFAOYSA-N 0.000 description 18
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 17
- 238000004519 manufacturing process Methods 0.000 description 17
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- VZXTWGWHSMCWGA-UHFFFAOYSA-N 1,3,5-triazine-2,4-diamine Chemical compound NC1=NC=NC(N)=N1 VZXTWGWHSMCWGA-UHFFFAOYSA-N 0.000 description 16
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 16
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- QEDNBHNWMHJNAB-UHFFFAOYSA-N tris(8-methylnonyl) phosphite Chemical compound CC(C)CCCCCCCOP(OCCCCCCCC(C)C)OCCCCCCCC(C)C QEDNBHNWMHJNAB-UHFFFAOYSA-N 0.000 description 1
- ZMPODEGAECKFEA-UHFFFAOYSA-N tris[2,4-bis(2-methylbutan-2-yl)phenyl] phosphite Chemical compound CCC(C)(C)C1=CC(C(C)(C)CC)=CC=C1OP(OC=1C(=CC(=CC=1)C(C)(C)CC)C(C)(C)CC)OC1=CC=C(C(C)(C)CC)C=C1C(C)(C)CC ZMPODEGAECKFEA-UHFFFAOYSA-N 0.000 description 1
- GTOWTBKGCUDSNY-UHFFFAOYSA-K tris[[ethyl(methyl)phosphoryl]oxy]alumane Chemical compound [Al+3].CCP(C)([O-])=O.CCP(C)([O-])=O.CCP(C)([O-])=O GTOWTBKGCUDSNY-UHFFFAOYSA-K 0.000 description 1
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- ITRNXVSDJBHYNJ-UHFFFAOYSA-N tungsten disulfide Chemical compound S=[W]=S ITRNXVSDJBHYNJ-UHFFFAOYSA-N 0.000 description 1
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- KOZCZZVUFDCZGG-UHFFFAOYSA-N vinyl benzoate Chemical compound C=COC(=O)C1=CC=CC=C1 KOZCZZVUFDCZGG-UHFFFAOYSA-N 0.000 description 1
- 239000004034 viscosity adjusting agent Substances 0.000 description 1
- 239000010456 wollastonite Substances 0.000 description 1
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- UGZADUVQMDAIAO-UHFFFAOYSA-L zinc hydroxide Chemical compound [OH-].[OH-].[Zn+2] UGZADUVQMDAIAO-UHFFFAOYSA-L 0.000 description 1
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- 229940007718 zinc hydroxide Drugs 0.000 description 1
- 229910052984 zinc sulfide Inorganic materials 0.000 description 1
- MFXMOUUKFMDYLM-UHFFFAOYSA-L zinc;dihydrogen phosphate Chemical compound [Zn+2].OP(O)([O-])=O.OP(O)([O-])=O MFXMOUUKFMDYLM-UHFFFAOYSA-L 0.000 description 1
- XAEWLETZEZXLHR-UHFFFAOYSA-N zinc;dioxido(dioxo)molybdenum Chemical compound [Zn+2].[O-][Mo]([O-])(=O)=O XAEWLETZEZXLHR-UHFFFAOYSA-N 0.000 description 1
- BNEMLSQAJOPTGK-UHFFFAOYSA-N zinc;dioxido(oxo)tin Chemical compound [Zn+2].[O-][Sn]([O-])=O BNEMLSQAJOPTGK-UHFFFAOYSA-N 0.000 description 1
- PZRXQXJGIQEYOG-UHFFFAOYSA-N zinc;oxido(oxo)borane Chemical compound [Zn+2].[O-]B=O.[O-]B=O PZRXQXJGIQEYOG-UHFFFAOYSA-N 0.000 description 1
- DRDVZXDWVBGGMH-UHFFFAOYSA-N zinc;sulfide Chemical compound [S-2].[Zn+2] DRDVZXDWVBGGMH-UHFFFAOYSA-N 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- 229910000166 zirconium phosphate Inorganic materials 0.000 description 1
- LEHFSLREWWMLPU-UHFFFAOYSA-B zirconium(4+);tetraphosphate Chemical compound [Zr+4].[Zr+4].[Zr+4].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LEHFSLREWWMLPU-UHFFFAOYSA-B 0.000 description 1
Classifications
-
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Description
で表されるユニットを有する化合物である。
前記式(1)において、R1は、炭化水素基、N−置換アミノ基、アミノ基含有炭化水素基、ヒドロキシル基、置換ヒドロキシル基などの有機基(特にヒドロキシル基又は置換ヒドロキシル基)、環Arは、C6-20芳香族炭化水素環(C6-12芳香族炭化水素環など)又は環の構成原子として1〜4個の窒素原子を有する6〜20員芳香族複素環、Y1及びY2で表される炭化水素基は、アルキル基、シクロアルキル基、アリール基、又はアラルキル基、Y1及びY2が隣接するリン原子とともに形成する環は、リン原子を環を構成するヘテロ原子として有する4〜20員ヘテロ環などであってもよい。前記有機リン化合物(B)は、下記式(2)〜(4)で表される化合物のうち少なくとも一種で構成されていてもよい。
で表される基を示し、d及びeは同一又は異なって、0又は1を示し、eが1である場合、dは1である。R1、Ar、X1、Y1、Y2、及びa〜cは前記に同じ]
前記式(3)及び(3a)において、環Y3とX1とX2とで形成されるリン含有基は下記式で表される基であってもよく、式中の芳香環には有機置換基(例えば、アルキル基、シクロアルキル基、アリール基、アラルキル基、アシル基、シアノ基など)を有してもよい。
このような難燃性樹脂組成物において、有機リン化合物(B)は下記式(2c)、(3b)、(3c)及び(4c)から選択された少なくとも一種の化合物であってもよい。
ベース樹脂(A)100重量部に対して、有機リン化合物(B)及び難燃助剤(C)の総量は0.01〜300重量部程度であってもよく、前記有機リン化合物(B)と前記難燃助剤(C)との割合は、前者/後者=5/100〜1000/100程度であってもよい。前記樹脂組成物は、さらに、ヒンダードフェノール系酸化防止剤、リン系安定剤、フッ素系樹脂、及び充填剤から選択された少なくとも一種を含んでもよい。
ベース樹脂としては、成形用として利用される種々の樹脂、例えば、ポリエステル系樹脂、スチレン系樹脂、ポリアミド系樹脂、ポリカーボネート系樹脂、ポリフェニレンオキシド系樹脂、ビニル系樹脂、オレフィン系樹脂、アクリル系樹脂などが挙げられる。
ポリエステル系樹脂は、ジカルボン酸成分とジオール成分との重縮合、オキシカルボン酸又はラクトンの重縮合、またはこれらの成分の重縮合などにより得られるホモポリエステル又はコポリエステルである。好ましいポリエステル系樹脂は、通常、飽和ポリエステル系樹脂、特に芳香族飽和ポリエステル系樹脂が含まれる。
スチレン系樹脂としては、例えば、スチレン系単量体(例えば、スチレン、ビニルトルエン、α−メチルスチレン、クロロスチレンなど)の単独又は共重合体;スチレン系単量体とビニル単量体(例えば、アクリロニトリルなどの不飽和ニトリル、(メタ)アクリル酸エステル、(メタ)アクリル酸、無水マレイン酸などのα,β−モノオレフィン性不飽和カルボン酸又は酸無水物あるいはそのエステルなど)との共重合体;スチレン系グラフト共重合体、スチレン系ブロック共重合体などが挙げられる。
ポリアミドには、ジアミンとジカルボン酸とから誘導されるポリアミド;アミノカルボン酸、必要に応じてジアミン及び/又はジカルボン酸を併用して得られるポリアミド;ラクタム、必要に応じてジアミン及び/又はジカルボン酸との併用により誘導されたポリアミドが含まれる。ポリアミドには、少なくとも2種の異なったポリアミド形成成分により形成されるコポリアミドも含まれる。
ポリカーボネート系樹脂には、ジヒドロキシ化合物と、ホスゲン又はジフェニルカーボネートなどの炭酸エステルとの反応により得られる重合体が含まれる。ジヒドロキシ化合物は、脂環族化合物などであってもよいが、好ましくはビスフェノール化合物である。
ポリフェニレンオキシド系樹脂(ポリフェニレンエーテル系樹脂)には、単独重合体および共重合体が含まれる。単独重合体としては、ポリ(2,6−ジメチル−1,4−フェニレン)オキシド、ポリ(2,5−ジメチル−1,4−フェニレン)オキシド、ポリ(2,5−ジエチル−1,4−フェニレン)オキシド、ポリ(2−メチル−6−エチル−1,4−フェニレン)オキシド、ポリ(2,6−ジ−n−プロピル−1,4−フェニレン)オキシド、ポリ(2−エチル−6−イソプロピル−1,4−フェニレン)オキシド、ポリ(2−メチル−6−メトキシ−1,4−フェニレン)オキシド、ポリ(2−メチル−6−ヒドロキシエチル−1,4−フェニレン)オキシド、ポリ(2,3,6−トリメチル−1,4−フェニレン)オキシド、ポリ(2,6−ジフェニル−1,4−フェニレン)オキシド、ポリ(2−メチル−6−フェニル−1,4−フェニレン)オキシド等のポリ(モノ、ジ又はトリC1-6アルキル−フェニレン)オキシド、ポリ(モノ又はジC6-20アリール−フェニレン)オキシド、ポリ(モノC1-6アルキル−モノC6-20アリール−フェニレン)オキシドなどが挙げられる。
ビニル系樹脂としては、ビニル系単量体(例えば、酢酸ビニル、プロピオン酸ビニル、クロトン酸ビニル、安息香酸ビニルなどのビニルエステル;塩素含有ビニル単量体(例えば、塩化ビニル、クロロプレン);フッ素含有ビニル単量体(例えば、フルオロエチレンなど);メチルビニルケトン、メチルイソプロペニルケトンなどのビニルケトン類;ビニルメチルエーテル、ビニルイソブチルエーテルなどのビニルエーテル類;N−ビニルカルバゾール、N−ビニルピロリドンなどのビニルアミン類など)の単独又は共重合体、あるいは他の共重合可能なモノマーとの共重合体などが含まれる。
オレフィン系樹脂としては、例えば、鎖状オレフィン(エチレン、プロピレンなどのα−C2-10オレフィンなど)、環状オレフィン、又はこれらの誘導体(アルキル置換体、カルボキシ置換体など)などの単独又は共重合体が挙げられる。前記環状オレフィンとしては、シクロアルケン(シクロプロペン、シクロブテン、シクロペンテン、シクロヘキセン、シクロオクテンなどのC3-10シクロアルケンなど)、シクロアルキン(シクロプロピン、シクロブチン、シクロペンチン、シクロヘキシン、シクロオクチンなどのC3-10シクロアルキンなど)、架橋環式シクロオレフィン(ノルボルネン、ジシクロペンタジエン、ジシクロヘプタジエン、テトラジシクロドデセン、ヘキサシクロヘプタデセンなど)などが挙げられる。
アクリル系樹脂には、例えば、(メタ)アクリル系単量体((メタ)アクリル酸又はそのエステルなど)の単独又は共重合体の他、(メタ)アクリル酸−スチレン共重合体、(メタ)アクリル酸メチル−スチレン共重合体などが含まれる。
その他の樹脂としては、ポリアセタール樹脂、ポリフェニレンスルフィド樹脂、脂肪族ポリケトン系樹脂(ケトン樹脂);ポリスルホン(例えば、熱可塑性ポリスルホン、ポリ(エーテルスルホン)、ポリ(4,4′−ビスフェノールエーテルスルホンなど);ポリエーテルケトン;ポリ(エーテルエーテルケトン);ポリエーテルイミド;熱可塑性ポリウレタン系樹脂(例えば、トリレンジイソシアネートなどのジイソシアネート化合物と、前記グリコール及び/又は前記ジアミンとの反応により得られる重合体、ポリテトラメチレングリコールなどのセグメントを有していてもよいポリウレタンエラストマーなど);熱可塑性ポリイミド;ポリオキシベンジレン;熱可塑性エラストマーなどが例示できる。
有機リン化合物(B)は、下記式(1a)で表されるユニットを有する化合物である。
このような有機リン化合物には、下記式(1)で表される化合物が含まれる。
前記式(1)において、R1で表される有機基としては、アルキル基[メチル、エチル、n−プロピル、イソプロピル、n−ブチル、sec−ブチル、t−ブチルなどのC1-10アルキル基(C1-6アルキル基、特にC1-4アルキル基など)など]、シクロアルキル基(シクロペンチル、シクロヘキシル基などのC5-10シクロアルキル基、特にC5-8シクロアルキル基など)、アリール基[フェニル、ナフチル基などのC6-20アリール基(C6-14アリール基、特にC6-10アリール基など)など]、アラルキル基[ベンジル、フェネチル基などのC6-20アリール−C1-6アルキル基(C6-14アリール−C1-6アルキル基、特にC6-10アリール−C1-4アルキル基など)など]などの炭化水素基;N−置換アミノ基[例えば、アミノ基の窒素原子に炭化水素基(前記例示の炭化水素基など)が1又は2個置換したN−置換アミノ基(N−アルキルアミノ基、N−アリールアミノ基など)又はN,N−二置換アミノ基(N,N−ジアルキルアミノ基、N,N−ジアリールアミノ基など)など];アミノ基含有炭化水素基[アミノ基を1又は複数(例えば、2〜4)個有する炭化水素基(前記例示の炭化水素基など)、例えば、アミノアルキル基(アミノC1-6アルキル基など)、アミノアリール基(モノ又はジアミノC6-10アリール基など)など];ヒドロキシル基;置換ヒドロキシル基(ヒドロキシル基の水素原子が置換された誘導体基)などが挙げられる。
で表される基を示し、d及びeは同一又は異なって、0又は1を示し、eが1である場合、dは1である。R1、Ar、X1、Y1、Y2、及びa〜cは前記に同じ]
前記式(2)〜(4)において、X2は、好ましくは酸素原子である。
式(2b)において、cは好ましくは1〜3の整数、さらに好ましくは1又は2、特に2である。
前記式(3b)において、cは好ましくは1〜3、さらに好ましくは1又は2、特に2である。
前記式(4b)において、cは好ましくは1〜3の整数、さらに好ましくは1又は2、特に2である。
例えば、R1としてヒドロキシル基(又は置換ヒドロキシル基)を有する化合物については、前記式(1)におけるAr−(OH)c(式中、Ar及びcは前記に同じ)に対応するキノン類[例えば、ベンゾキノン類(1,4−ベンゾキノン、1,2−ベンゾキノンなど)、ナフトキノン類(1,4−ナフトキノン、1,2−ナフトキノン、2,6−ナフトキノンなど)、4,4’−ジフェノキシキノン、2,2’−ジフェノキシキノン、3,10−ペリレンキノンなど]と前駆体(例えば、9,10−ジヒドロ−9−オキサ−10−ホスファフェナントレン−10−オキシド類、2級ホスフィンオキシド類、亜ホスフィン酸エステルなど)とを不活性溶媒中で加熱反応させることにより得られる。
本発明では、難燃助剤(C)には、リン含有化合物(C1)[(c1)無機リン化合物、(c2)オルトリン酸エステル又はその縮合物、(c3)リン酸エステルアミド、(c4)ホスホニトリル化合物、(c5)ホスホニル基又はホスフィニコ基を有する亜リン酸エステル又はその金属塩、及び(c6)ホスホニル基又はホスフィニコ基を有する有機ホスフィン酸化合物又はその金属塩など]、芳香族樹脂(C2)、窒素含有化合物(C3)(非リン系の窒素含有環状化合物又はその塩など)、無機金属系化合物(C4)ケイ素含有化合物(C5)、硫黄含有化合物(C6)などが含まれる。これらの難燃助剤は、単独で又は二種以上組み合わせて使用できる。
リン含有化合物(C1)には、前記有機リン化合物(B)を除くリン化合物、例えば、(c1)無機リン化合物、モノマー型有機リン化合物[(c2)オルトリン酸エステル又はその縮合物、(c3)リン酸エステルアミド、(c4)ホスホニトリル化合物、(c5)ホスホニル基(>P(=O)H)又はホスフィニコ基(>P(=O)OH)を有する亜リン酸エステル又はその金属塩、(c6)ホスホニル基又はホスフィニコ基を有する有機ホスフィン酸化合物又はその金属塩、(c7)ホスフィンオキシド(トリフェニルホスフィンオキシド、トリクレジルホスフィンオキシドなど)など]、前記モノマー型有機リン化合物の縮合物であるポリマー型有機リン化合物などが含まれる。これらのリン含有化合物は、一種で又は二種以上組み合わせて使用できる。
無機リン化合物には、例えば、赤リン、(ポリ)リン酸塩[オルトリン酸、亜リン酸、次亜リン酸、ポリリン酸(メタリン酸、ピロリン酸、三リン酸、四リン酸等)、ポリ亜リン酸(メタ亜リン酸、ピロ亜リン酸等)などの非縮合又は縮合リン酸類のアンモニウム塩又は金属塩(Ca、Mg、Zn、Ba、Al塩など)など]、リン酸ホウ素などが含まれる。
オルトリン酸エステルとしては、脂肪族オルトリン酸エステル[リン酸トリメチル、リン酸トリエチル、リン酸トリプロピル、リン酸トリイソプロピル、リン酸トリブチル、リン酸トリイソブチル、リン酸ペンタエリスリトール(例えば、Great Lakes Chemical社のNH−1197、特開2001−106889号公報に記載のビシクロリン酸エステルなど)などのオルトリン酸トリC1-10アルキルエステル;前記オルトリン酸トリエステルに対応するオルトリン酸ジC1-10アルキルエステル及びリン酸モノC1-10アルキルエステルなど]、芳香族オルトリン酸エステル[リン酸トリフェニル、リン酸トリクレジル、リン酸トリキシリル、リン酸ジフェニルクレジル、リン酸トリ(イソプロピルフェニル)、リン酸ジフェニルエチルクレジルなどのオルトリン酸トリC6-20アリールエステルなど]、脂肪族−芳香族オルトリン酸エステル[リン酸メチルジフェニル、リン酸フェニルジエチル、スピロ環状芳香族オルトリン酸エステル(ジフェニルペンタエリスリトールジホスフェート、ジクレジルペンタエリスリトールジホスフェート、ジキシリルペンタエリスリトールジホスフェートなど)など]などが挙げられる。
リン酸エステルアミドとしては、リン酸エステル及びリン酸アミドの結合様式を含み、特開2001−354684号公報、特開2001−139823号公報、特開2000−154277号公報、特開平10−175985号公報、特開平8−59888号公報、特開昭63−235363号公報に記載のリン酸エステルアミドなどが使用できる。
ホスホニトリル化合物としては、例えば、(ポリ)フェノキシホスファゼン、(ポリ)トリルオキシホスファゼン、(ポリ)キシリルオキシホスファゼン、(ポリ)メチルナフチルオキシホスファゼン等の環状又は鎖状アリールオキシホスファゼン、(ポリ)メトキシフェノキシホスファゼン、(ポリ)メトキシトリルオキシホスファゼン、(ポリ)メトキシナフチルオキシホスファゼン等の環状又は鎖状アルコキシアリールオキシホスファゼン、(ポリ)メトキシホスファゼンなどの環状又は鎖状アルコキシホスファゼン等が例示できる。また、アリールオキシホスファゼン又はアルコキシホスファゼンの誘導体(例えば、ハイドロキノン、レゾルシノール、ビフェノール、ビスフェノール類で変性された環状及び/又は鎖状フェノキシホスファゼンなど)なども前記ホスホニトリル化合物に含まれる。
有機ホスホン酸(亜リン酸)化合物には、ホスホニル基(>P(=O)H)又はホスフィニコ基(>P(=O)OH)を有する亜リン酸エステル又はその金属塩が含まれる。また、有機ホスホン酸化合物には、亜リン酸トリエステル、ホスホノカルボン酸エステル又はその金属塩なども含まれる。これらの有機ホスホン酸化合物は一種で又は二種以上組み合わせて使用できる。
ホスホニル基を有する有機ホスフィン酸化合物としては、アルキル基(C1-4アルキル基など)又はアリール基(C6-10アリール基など)が一置換していてもよいホスフィン酸エステル(ホスフィン酸メチルなどのホスフィン酸C1-6アルキル、ホスフィン酸フェニルなどのホスフィン酸C6-10アリール[10−C1-30アルキル置換−9,10−ジヒドロ−9−オキサ−10−ホスファフェナントレン−10−オキシドなどの環状ホスフィン酸エステル]など)などが含まれる。
前記ポリマー型有機リン化合物としては、モノマー型有機リン化合物の縮合物、例えば、ポリマー型リン酸エステル(すなわち、縮合リン酸エステル、例えば、前記オルトリン酸モノアルキル又はアリールエステルの縮合物など)を用いることができる。
芳香族樹脂には、ポリフェニレンスルフィド系樹脂、ポリフェニレンオキシド系樹脂、ポリカーボネート系樹脂、ポリアリレート系樹脂、芳香族ナイロン、ポリエーテルイミド系樹脂、芳香族エポキシ樹脂、ノボラック樹脂、アラルキル樹脂、芳香族ビニル樹脂等の炭化性又はチャー形成性芳香族樹脂が含まれる。ポリフェニレンオキシド系樹脂及びポリカーボネート系樹脂としては、前記ベース樹脂の項で例示した樹脂と同様の樹脂を使用することができ、ベース樹脂と芳香族樹脂とは、通常、異種の樹脂が使用される。
ポリフェニレンスルフィド系樹脂(ポリフェニレンチオエーテル系樹脂)としては、ポリフェニレンスルフィド骨格−(Ar1−S−)−[式中、Ar1はフェニレン基を示す]を有する単独重合体及び共重合体が含まれる。フェニレン基(−Ar1−)としては、例えば、p−フェニレン基、m−フェニレン基、o−フェニレン基、置換フェニレン基(例えば、C1-5アルキル基などの置換基を有するアルキルフェニレン基や、フェニル基などの置換基を有するアリールフェニレン基)、p,p′−ジフェニレンスルホン基、p,p′−ビフェニレン基、p,p′−ジフェニレンエーテル基、p,p′−ジフェニレンカルボニル基等が例示できる。ポリフェニレンスルフィド系樹脂は、このようなフェニレン基で構成されるフェニレンスルフィド基のうち、同一の繰返し単位を用いたホモポリマーであってもよく、組成物の加工性の点から、異種繰返し単位を含むコポリマーであってもよい。
難燃剤を構成する芳香族ナイロンとしては、前記ベース樹脂のポリアミド樹脂とは異種の樹脂が使用される。このような樹脂としては、下記式(5)で表される単位を有する化合物などが使用できる。
ポリアリレート系樹脂には、下記式(6)
[−O−Ar2−OC(O)−A1−C(O)−] (6)
(式中、Ar2は芳香族基を示し、A1は芳香族、脂環族、又は脂肪族基を示す)
で表される構造単位を有する化合物が使用できる。
芳香族エポキシ樹脂には、エーテル系エポキシ樹脂[例えば、ビフェニル型エポキシ樹脂(例えば、3,3’5,5’−テトラメチルビフェノール型エポキシ樹脂など)、ビスフェノール型エポキシ樹脂、ノボラック型エポキシ樹脂、不飽和環状炭化水素化合物により変性されたエポキシ樹脂(例えば(ジ)シクロペンタジエン型エポキシ樹脂など)、スチルベン型エポキシ樹脂など]、芳香族アミン成分を用いたアミン系エポキシ樹脂などが含まれる。
ヒドロキシル基及び/又はアミノ基を有する芳香族環を有する樹脂としては、前記芳香族環を主鎖又は側鎖に有する樹脂が挙げられる。こられの樹脂のうち、芳香族環を主鎖に有する樹脂としては、例えば、ノボラック樹脂、アラルキル樹脂、不飽和環状炭化水素化合物により変性されたフェノール樹脂[例えば、(ジ)シクロペンタジエン型フェノール樹脂、特開昭61−291616号公報、特開昭62−201922号公報、特開平6−49181号公報記載のフェノール樹脂など]が例示でき、芳香族環を側鎖に有する樹脂としては、芳香族ビニル樹脂が例示できる。
ノボラック樹脂は、下記式(7)で表される繰り返し単位を有している。
アラルキル樹脂は、下記式(8)で表される構造単位を有している。
(式中、Y6はアルコキシ基、アシルオキシ基、ヒドロキシル基又はハロゲン原子を示す。Ar3、Z5及びZ6は前記に同じ)。
芳香族ビニル樹脂としては、例えば、下記式(11)で表される構造単位を有する樹脂が使用できる。
難燃助剤として用いられる窒素含有化合物としては、前記有機リン化合物とは異なり、非リン系の窒素含有環状化合物(分子内にリン含有基を含まない窒素含有環状化合物、例えば、非リン系のアミノ基を有する窒素含有環状化合物又はその塩、環状尿素化合物、及びテトラゾール化合物など)又はその塩が使用できる。また、窒素含有化合物(C3)として、(ポリ)リン酸アミドや非環状尿素化合物などを用いてもよい。このような窒素含有化合物(C3)は、一種で又は二種以上組み合わせて使用できる。
非リン系のアミノ基を有する窒素含有環状化合物には、少なくとも1つのアミノ基と、少なくとも1つの窒素原子を環のヘテロ原子として有するヘテロ環状化合物が含まれ、ヘテロ環は、窒素以外にイオウ、酸素などの他のヘテロ原子を有していてもよい。このような窒素含有ヘテロ環には、窒素含有5員環(ピロール、ピラゾリン、イミダゾール、トリアゾール等)、窒素及び硫黄含有5員環(チアゾリン、チアゾール、チアジアゾール、チアジアゾリン等)、窒素及び酸素含有5員環(オキサゾリン、フラザン等)、窒素含有6員環(ピリジン、ピラジン、ピリミジン、ピリダジン、トリアジン等)、窒素及び酸素含有6員環(オキサジンなど)、窒素及び硫黄含有6員環(チアジン、チアジアジン等)、縮合複素環(インドール、インダゾール、キノリン、プリン等)などの複数の窒素原子を環の構成原子として有する5又は6員不飽和窒素含有ヘテロ環などが含まれる。このような窒素含有環のうち、複数の窒素原子を環の構成原子として有する5又は6員不飽和窒素含有環が好ましく、特に、トリアゾール及びトリアジンが好ましい。
アミノ基を有する窒素含有環状化合物としては、前記(a)と同様の窒素含有環状化合物が使用できる。
酸素酸には、硝酸、塩素酸(過塩素酸、塩素酸、亜塩素酸、次亜塩素酸など)、リン酸、硫酸、スルホン酸、ホウ酸、クロム酸、アンチモン酸、モリブデン酸、タングステン酸、スズ酸、ケイ酸などが含まれる。好ましい酸素酸には、リン酸(ポリリン酸)、硫酸、スルホン酸、ホウ酸が含まれる。
リン酸には、ペルオクソリン酸、オルトリン酸、メタリン酸、亜リン酸(ホスホン酸)、次亜リン酸(ホスフィン酸)などの非縮合リン酸;ポリメタリン酸(HPO3)j(式中、jは、2以上の整数を示す)、次リン酸、無水リン酸(五酸化二リン)などの縮合リン酸(ポリリン酸)などが含まれる。また、前記ポリリン酸には下記式(13)で表される縮合リン酸類も含まれる。
硫酸としては、ペルオクソ一硫酸、硫酸、亜硫酸等の非縮合硫酸、ペルオクソ二硫酸やピロ硫酸等の縮合硫酸などが挙げられる。
スルホン酸としては、C1-10アルカンスルホン酸(例えば、メタンスルホン酸、エタンスルホン酸、エタンジスルホン酸など)、C6-20アレーンスルホン酸(例えば、ベンゼンスルホン酸、トルエンスルホン酸など)等の有機スルホン酸が挙げられる。
ホウ酸としては、オルトホウ酸、メタホウ酸などの非縮合ホウ酸;四ホウ酸、無水ホウ酸などの縮合ホウ酸などが挙げられる。
アミノ基を有する窒素含有環状化合物としては、前記(a)と同様のアミノ基を有する窒素含有環状化合物が例示できる。
アミノ基を有する窒素含有環状化合物としては、前記(a)の項で例示したアミノ基を有する窒素含有環状化合物が例示できる。
尿素化合物には、環状尿素化合物が含まれる。また、非環状尿素化合物を使用してもよい。尿素化合物は、一種で又は二種以上組み合わせて使用できる。
環状尿素化合物は、少なくとも1つの尿素ユニット−NHCONH−を環の構成ユニットとして有する限り、特に制限されず、単環化合物、芳香族炭化水素環との縮合環、架橋環などのいずれであってもよい。このような環状尿素化合物には、環状モノウレイド、環状ジウレイド等が挙げられる。これらの環状尿素化合物は、単独で又は二種以上組み合わせて使用できる。
非環状尿素化合物には、尿素、アルキル基などの置換基が置換したN−置換尿素[例えば、N−メチル体、N−エチル体などのN−C1-6アルキル体、アルキレンジウレア(例えば、メチレンジウレアなどのC1-6アルキレンジウレアなど)など]、非環状ウレイド化合物[オキサルル酸などのC2-6ジカルボン酸のウレイド酸、ウレイド酢酸などのウレイド基含有C1-6モノカルボン酸、ウレイドコハク酸などのカルバミド基含有C2-6ジカルボン酸、又はそれらの誘導体(アミド、エステルなど)などのモノウレイド;アラントイン酸などのC2-6カルボン酸のジウレイドなど]非環状の尿素縮合体[尿素の二量体(例えば、ビウレット、ビウレアなど)尿素の多量体、尿素とアルデヒド化合物との縮合体など]などが含まれる。
テトラゾール化合物には、モノテトラゾール(5−フェニルテトラゾールなど)及びビテトラゾール(5,5′−ビテトラゾールなど)のアミン塩又は金属塩が含まれる。アミン塩としては、5−フェニルテトラゾール、5,5′−ビテトラゾールのアミン塩(例えば、2アンモニウム塩、2グアニジン塩、ピペラジン塩、メラミン塩、グアナミン塩、キシリレンジアミン塩など)などが挙げられる。金属塩としては、5,5′−ビテトラゾールの金属塩(例えば、Na塩、K塩などのアルカリ金属塩;Ca塩、Mg塩、Ba塩などのアルカリ土類金属塩;Zn塩、Al塩など)などが挙げられる。
(ポリ)リン酸アミドとしては、前記酸素酸の項で例示したリン酸類と、−N=C=N−又は−N=C(−N<)2で表されるユニットを有する化合物(シアナミド誘導体など)との縮合物であり、アミド態の窒素を含有する高分子化合物である。このような(ポリ)リン酸アミドは、通常、前記リン酸と前記シアナミド誘導体とを、尿素及びリン酸尿素から選択された少なくとも一種(結合剤)の存在下で加熱(焼成など)することにより得られる。
無機金属系化合物には、無機酸の金属塩、金属酸化物、金属水酸化物、及び金属硫化物などが含まれる。前記無機酸の金属塩を構成する無機酸としては、リン酸、ホウ酸、スズ酸、モリブデン酸、タングステン酸等の各種無機酸が使用できる。
リン酸としては、非縮合リン酸[オルトリン酸、メタリン酸、亜リン酸、次亜リン酸等]、縮合リン酸[次リン酸塩、ピロリン酸塩、ポリリン酸(三リン酸、四リン酸等)、ポリメタリン酸、無水リン酸塩類等]が例示でき、特に非縮合リン酸が好ましい。
ホウ酸としては、オルトホウ酸、メタホウ酸などの非縮合ホウ酸;ピロホウ酸、四ホウ酸、五ホウ酸及び八ホウ酸などの縮合ホウ酸、並びに塩基性ホウ酸などが好ましい。
スズ酸としては、スズ酸、メタスズ酸、オルトスズ酸、ヘキサヒドロオクソスズ酸等が例示できる。金属としては、アルカリ金属や、アルカリ土類金属、遷移金属、周期表2B族金属等の多価金属が例示できる。スズ酸の金属塩は、通常、含水塩であり、例えば、スズ酸のアルカリ金属塩(例えば、スズ酸ナトリウムやスズ酸カリウム等)、スズ酸のアルカリ土類金属塩(例えば、スズ酸マグネシウムなど)、スズ酸の遷移金属塩(例えば、スズ酸コバルトなど)、スズ酸の周期表2B族金属塩(例えば、スズ酸亜鉛など)が例示できる。これらのスズ酸の金属塩のうち、スズ酸の周期表2B族金属塩、特に(含水)スズ酸亜鉛類が好ましい。
モリブデン酸の金属塩としては、前記リン酸金属塩及びホウ酸金属塩に対応する各種金属塩が使用できる。
タングステン酸の金属塩としては前記リン酸金属塩及びホウ酸金属塩に対応する各種金属塩が使用できる。
硫黄含有化合物としては、有機スルホン酸[アルカンスルホン酸、パーフルオロアルカンスルホン酸(パーフルオロブタンスルホン酸など)、アレーンスルホン酸(ベンゼンスルホン酸、トルエンスルホン酸、ナフタレンスルホン酸、スルホ安息香酸、スルホフタル酸、スルホナフトエ酸、フェノールスルホン酸、ナフトールスルホン酸、ジフェニルスルホン−3−スルホン酸など)、スルホン化ポリマー(スルホン化ポリスチレン、スルホン化ポリスルホン、スルホン化ポリエーテルスルホン、スルホン化ポリフェニレンオキシドなど)など]、スルファミン酸、有機スルファミン酸、有機スルホン酸アミドの塩(アンモニウム塩、アルカリ金属塩、アルカリ土類金属塩など)などが挙げられる。
ケイ素含有化合物には、(ポリ)オルガノシロキサン(樹脂、エラストマー、オイルなど)、ゼオライトなどが含まれる。(ポリ)オルガノシロキサンとしては、ジアルキルシロキサン(例えば、ジメチルシロキサンなど)、アルキルアリールシロキサン(フェニルメチルシロキサンなど)、ジアリールシロキサン、モノオルガノシロキサンなどの単独重合体(例えば、ポリジメチルシロキサン、ポリフェニルメチルシロキサンなど)、又は共重合体などが含まれる。また、(ポリ)オルガノシロキサンとしては、分岐オルガノシロキサン(ポリメチルシルセスキオキサン、ポリメチルフェニルシルセスキオキサン、ポリフェニルシルセスキオキサンなどのポリオルガノシルセスキオキサンなど)[例えば、東芝シリコーン(株)の商品名「XC99−B5664」、信越化学工業(株)の商品名「X−40−9243」、「X−40−9244」、「X−40−9805」、特開2001−41219号公報、特開2000−159995公報、特開平11―158363号公報、特開平10−182832号公報、特開平10−139964号公報などに記載の化合物など]、分子端末や主鎖に、エポキシ基、水酸基、カルボキシル基、アミノ基、エーテル基などの置換基を有する変性(ポリ)オルガノシロキサン[例えば、東レ・ダウコーニング−シリコーン(株)の商品名Siパウダー「DC4−7051」、「DC4−7105」、「DC1−9641」]なども使用できる。
(有機リン化合物(B)の使用割合)
本発明では、難燃剤として特定の有機リン化合物(B)を用いることにより、幅広いベース樹脂に対して、少量の添加であっても高い難燃性を付与できる。有機リン化合物(B)の割合は、ベース樹脂(A)100重量部に対して、0.1〜100重量部、好ましくは1〜80重量部、さらに好ましくは5〜70重量部程度である。ベース樹脂(A)に対して有機リン化合物(B)の割合が多すぎると、樹脂組成物の機械的特性が低下する。
難燃助剤(C)の割合は、ベース樹脂(A)100重量部に対して、0.01〜500重量部、好ましくは0.1〜300重量部、さらに好ましくは1〜200重量部程度である。
本発明の難燃性樹脂組成物は、必要に応じて種々の添加剤(例えば、他の難燃剤、ドリッピング防止剤、酸化防止剤、安定剤など)を含んでいてもよい。添加剤の全体の含有量は、ベース樹脂(A)100重量部に対して、0.01〜50重量部、好ましくは、0.1〜30重量部、さらに好ましくは1〜20重量部程度である。
なお、本発明の難燃性樹脂組成物は、さらに難燃性を付与するため、他の難燃剤、例えば、アルコール系難燃剤、無機系難燃剤、ラジカル発生有機系難燃剤などを含んでいてもよい。
本発明の難燃性樹脂組成物は、機械的強度、剛性、耐熱性及び電気的性質などをさらに向上させるため、充填剤により改質されていてもよい。充填剤には、繊維状充填剤、非繊維充填剤(板状充填剤、粉粒状充填剤など)が含まれる。
本発明の難燃性樹脂組成物は、粉粒体混合物や溶融混合物であってもよく、ベース樹脂と、難燃剤と、難燃助剤と、必要によりドリッピング防止剤や他の添加剤などとを慣用の方法で混合することにより調製できる。例えば、(1)各成分を混合して、一軸又は二軸の押出機により混練し押出してペレットを調製した後、成形する方法、(2)一旦、組成の異なるペレット(マスターバッチ)を調製し、そのペレットを所定量混合(希釈)して成形に供し、所定の組成の成形品を得る方法、(3)成形機に各成分の1又は2以上を直接仕込む方法などが採用できる。さらに、押出機によるペレットの製造方法としては、(1)脆性充填剤(ガラス系充填剤など)を除く成分を先に溶融混合した後に、脆性充填剤成分を混合する製造方法、(2)リン系化合物及び脆性充填剤を除く成分を先に溶融混合した後に、脆性充填剤及びリン系化合物を(同じフィード位置で)同時混合する製造方法、(3)リン系化合物及び脆性充填剤を除く成分を先に溶融混合した後に、脆性充填剤及びリン系化合物を(別々のフィード位置で)順次混合する製造方法等が採用できる。この押出機によるペレット製造において、少量の芳香族化合物やハロゲン化合物(ベンゼン、トルエン、キシレン、クロロベンゼン、トリクロロベンゼン、クロロホルム、トリクロロエチレンなど)を分散助剤として押出時に配合してもよい。この分散助剤は押出機のベント口から混練樹脂より除去される。また、成形品に用いられる組成物の調製において、ベース樹脂の粉粒体(例えば、ポリエステル系樹脂の一部又は全部を粉砕した粉粒体)と、他の成分(難燃剤など)とを混合して溶融混練すると、他の成分の分散を向上させるのに有利である。
(燃焼性試験)
UL94に準拠して、試験片の厚み1.6mmで燃焼性を評価した。
(ブルーミング性の評価)
1.6mmの燃焼試験片を150℃で5時間加熱し、試験片表面の染み出し状態を目視観察し、以下の判断基準によりブルーミング性を評価した。
△:若干の染み出しが見られる
×:著しい染み出しが見られる。
A−1:ポリブチレンテレフタレート[ジュラネックス、固有粘度=0.83、ポリプラスチックス(株)製]
A−2:ポリスチレン[トーヨースチロールG19、東洋スチレン(株)製]
A−3:アクリロニトリル−スチレン共重合体[セビアンJD、ダイセル化学工業(株)製]
A−4:ポリエチレンテレフタレート[ベルペットEFG10、カネボウ合繊(株)製]
A−5:12mol%イソフタル酸変性ポリブチレンテレフタレートコポリマー[固有粘度=1.0]
A−6:ポリカーボネート[パンライトL1225、帝人化成(株)製]
A−7:アクリロニトリル−ブタジエン−スチレン共重合体[セビアンDP611、ダイセル化学工業(株)製]
A−8:液晶性ポリエステル[ロッドランLC3000、ユニチカ(株)製]
A−9:液晶性ポリエステル[ベクトラA950、ポリプラスチックス(株)製]
A−10:ポリ(2,6−ジメチル−1,4−フェニレン)オキシド[PPEポリマーYPX−100F、三菱ガス化学(株)製]
A−11:ナイロン−6[UBEナイロン6、宇部興産(株)製]
A−12:ポリトリメチレンテレフタレート[固有粘度=1.0]。
B−1:10−(2,5−ジヒドロキシフェニル)−10H−9−オキサ−10−ホスファフェナントレン−10−オキシド
B−2:10−(2,7−ジヒドロキシナフチル)−10H−9−オキサ−10−ホスファフェナントレン−10−オキシド
B−3:ジフェニルホスホニル−1,4−ハイドロキノン
B−4:シクロオクチレンホスホニルハイドロキノン[1’,4’−シクロオクチレンホスホニル−1,4−ハイドロキノンと1’,5’−シクロオクチレンホスホニル−1,4−ハイドロキノンとの混合物]
B−5:1,4−ビス[(9,10−ジヒドロ−9−オキサ−10−オキシド−10−ホスファフェナントレン−10−イル)メチル]ベンゼン
B−6:含リンポリアリレート[化合物B−1のジアセテートとテレフタル酸/イソフタル酸(モル比:50/50)から重縮合反応により調製した含リンポリアリレート]
B−7:N,N’−ビス[(9,10−ジヒドロ−9−オキサ−10−オキシド−10−ホスファフェナントレン−10−イル)メチル]ベンゾグアナミン[HCA−BG、三光(株)製]
B−8:[(9,10−ジヒドロ−9−オキサ−10−オキシド−10−ホスファフェナントレン−10−イル)メチル]ベンゼン[BCA(10−ベンジル−9,10−ジヒドロ−9−オキサ−10−ホスファフェナントレン−10−オキシド)、三光(株)製]
B−9:1,4−ビス[(シクロオクチレンホスホニル)メチル]ベンゼン(1,4−ビス[(1’,4’−シクロオクチレンホスホニル)メチル]ベンゼンと1,4−ビス[(1’,5’−シクロオクチレンホスホニル)メチル]ベンゼンとの混合物)
B−10:[(シクロオクチレンホスホニル)メチル]ベンゼン([(1,4−シクロオクチレンホスホニル)メチル]ベンゼンと[(1,5−シクロオクチレンホスホニル)メチル]ベンゼンとの混合物)。
B−11:9,10−ジヒドロ−9−オキサ−10−ホスファフェナントレン−10−オキシド
B−12:レゾルシノールビス(ジフェニルホスフェート)。
[リン含有化合物 C1]
C1−1:赤燐[ノーバエクセル140、燐化学工業(株)製]
C1−2:エチルメチルホスフィン酸アルミニウム[特開平11−60924号公報の実施例に準じて調製した。]
C1−3:レゾルシノールビス(ジ−2,6−キシリルホスフェート)
C1−4:1,4−ピペラジンジイルテトラ−2,6−キシリルホスフェート[N,N′−ビス(ジ−2,6−キシリルオキシホスフィニル)ピペラジン]
C1−5:ポリフェノキシホスファゼン。
C2−1:ポリカーボネート[ユーピロンS3000、三菱ガス化学(株)製]
C2−2:ポリアリレート[ポリアリレートU100、ユニチカ(株)製]
C2−3:ナイロンMXD6[レニー6002、三菱エンジニアリングプラスチックス(株)製]
C2−4:ポリ(2,6−ジメチル−1,4−フェニレン)オキシド[PPEポリマーYPX−100F、三菱ガス化学(株)製]
C2−5:ノボラック型フェノール樹脂[PR−53647、住友デュレズ(株)製]
C2−6:フェノールアラルキル樹脂[ミレックスXL−225、三井化学(株)製]
C2−7:ポリ(1,4−フェニレン)スルフィド
C2−8:フェノキシ樹脂[フェノトートYP−50、東都化成(株)製]
C2−9:ビスフェノールA型エポキシ樹脂[エピコート1004K、油化シェルエポキシ(株)製]
C2−10:ポリp−ビニルフェノール[マルカリンカーMS−1P、丸善石油化学(株)製]
C2−11:フェノールノボラック型エポキシ樹脂[EPPN−201、日本化薬(株)製]。
C3−1:メラミンシアヌレート[MC610、日産化学工業(株)製]
C3−2:ポリリン酸メラム[PMP200、日産化学工業(株)製]
C3−3:ポリリン酸メラミン[Melapur200、DSM(株)製]
C3−4:硫酸メラミン[アピノン−901、(株)三和ケミカル製]
C3−5:5,5’−ビテトラゾールのピペラジン塩
C3−6:アセチレン尿素。
C4−1:硼酸亜鉛[FireBrake ZB、ボラックス・ジャパン(株)製]
C4−2:無水リン酸一水素カルシウム[平均粒子径=約30μm、太平化学産業(株)製]
C4−3:水酸化マグネシウム[キスマ5E、協和化学工業(株)製]
C4−4:硼酸亜鉛[FireBrake 415、ボラックス・ジャパン(株)製]。
C5−1:スルホン化ポリスチレンのナトリウム塩[ライオン(株)製]
[ケイ素含有化合物 C6]
C6−1:ゼオライト[ゼオラムA−3,東ソー(株)製]
C6−2:シリコーン樹脂[SiパウダーDC4−7015、東レ・ダウコーニングシリコーン(株)製]
C6−3:シリコーン樹脂[X−40−9805、信越化学工業(株)製]。
D−1:ペンタエリスリトール−テトラキス[3−(3,5−ジ−t−ブチル−4−ヒドロキシフェニル)プロピオネート][イルガノックス1010、チバガイギー(株)製]。
E−1:ビス(2,6−ジ−t−ブチル−4−メチルフェニル)ペンタエリスリトールジホスファイト[アデカスタブPEP36、アデカアーガス(株)製]
E−2:テトラキス(2,4−ジ−t−ブチルフェニル)−4,4′−ビフェニレンジホスホナイト[サンドスタブP−EPQ、サンド(株)製]。
F−1:ポリテトラフルオロエチレン
[充填剤 G]
G−1:直径10μm、長さ3mmのガラスチョップドストランド
G−2:タルク[タルク3A、日本タルク(株)製]。
上記成分を表1〜表11の割合(重量部)で混合し、小型混練機[東洋精機(株)製]により樹脂組成物を調製した。この樹脂組成物をプレス成形により試験用成形品を作製し、特性を評価した。
結果を表1〜表11に示す。
Claims (12)
- ベース樹脂(A)と、有機リン化合物(B)と、難燃助剤(C)とで構成された難燃性樹脂組成物であって、
前記ベース樹脂(A)が、ポリエステル系樹脂、又は少なくともポリエステル系樹脂とスチレン系樹脂とで構成された樹脂であり、
前記有機リン化合物(B)が、
(B1)ジアリールホスホニル−ポリヒドロキシアレーン類、ジアルキルホスホニル−ポリヒドロキシアレーン類、10−(ポリヒドロキシアリール)−10H−9−オキサ−10−ホスファフェナントレン−10−オキシド類、及びシクロアルキレンホスホニル−ポリヒドロキシアレーン類から選択された少なくとも一種、
(B2)モノ又はビス[(9,10−ジヒドロ−9−オキサ−10−オキシド−10−ホスファフェナントレン−10−イル)C 1−4 アルキル]ベンゼン類、N−モノ又はN,N−ビス[(9,10−ジヒドロ−9−オキサ−10−オキシド−10−ホスファフェナントレン−10−イル)C 1−4 アルキル]アミノトリアジン類、モノ又はビス[(シクロアルキレンホスホニル)C 1−4 アルキル]ベンゼン類、及びN−モノ又はN,N−ビス[(シクロアルキレンホスホニル)C 1−4 アルキル]アミノトリアジン類から選択された少なくとも一種、又は
(B3)下記式(1)
で表される化合物と、少なくとも芳香族ジカルボン酸を含むジカルボン酸成分とから得られるオリゴマー又はポリマーであり、
前記難燃助剤(C)が(C1)(c1)無機リン化合物、(c2)オルトリン酸エステル又はその縮合物、(c3)リン酸エステルアミド、(c4)ホスホニトリル化合物、(c5)ホスホニル基又はホスフィニコ基を有する亜リン酸エステル又はその金属塩、及び(c6)ホスホニル基又はホスフィニコ基を有する有機ホスフィン酸化合物又はその金属塩から選択されたリン含有化合物、(C2)ベース樹脂(A)と異種の芳香族樹脂であって、ポリフェニレンスルフィド系樹脂、ポリフェニレンオキシド系樹脂、ポリカーボネート系樹脂、芳香族ナイロン、ポリアリレート系樹脂、芳香族エポキシ樹脂、並びにヒドロキシル基及び/又はアミノ基を有する芳香族環を主鎖又は側鎖に有する樹脂から選択された少なくとも一種の芳香族樹脂、(C3)窒素含有環状化合物又はその塩、(C4)無機金属系化合物、(C5)硫黄含有化合物、及び(C6)ケイ素含有化合物から選択された少なくとも一種であり、
ベース樹脂(A)と芳香族樹脂(C2)との割合(重量比)が、前者/後者=60/40〜100/0である難燃性樹脂組成物。 - ポリエステル系樹脂が、1,4−シクロヘキサンジメチレンテレフタレート、C2−4アルキレンテレフタレート及びC2−4アルキレンナフタレートから選択された少なくとも1種の単位を有するホモ又はコポリエステルである請求項1記載の樹脂組成物。
- ポリエステル系樹脂が、エチレンテレフタレート、トリメチレンテレフタレート、及びブチレンテレフタレートから選択された少なくとも一種の単位をホモ又はコポリエステルである請求項1記載の樹脂組成物。
- 難燃助剤(C)が窒素含有環状化合物又はその塩(C3)を含み、かつ窒素含有環状化合物又はその塩(C3)が、非リン系のアミノ基を有する窒素含有環状化合物又はその塩、環状尿素化合物、テトラゾール化合物及び(ポリ)リン酸アミドから選択された少なくとも一種である請求項1記載の樹脂組成物。
- 難燃助剤(C)が無機金属系化合物(C4)を含み、かつ無機金属系化合物(C4)が、金属水酸化物、硼酸金属塩、リン酸水素金属塩、錫酸金属塩から選択された少なくとも一種である請求項1記載の樹脂組成物。
- 難燃助剤(C)が硫黄含有化合物(C5)を含み、かつ硫黄含有化合物(C5)が、有機スルホン酸金属塩から選択された少なくとも一種である請求項1記載の樹脂組成物。
- 難燃助剤(C)がケイ素含有化合物(C6)を含み、かつケイ素含有化合物(C6)が、直鎖又は分岐状オルガノシロキサン、及びゼオライトから選択された少なくとも一種である請求項1記載の樹脂組成物。
- ベース樹脂(A)100重量部に対して、有機リン化合物(B)及び難燃助剤(C)の総量が0.01〜300重量部であり、前記有機リン化合物(B)と前記難燃助剤(C)との割合が、前者/後者=5/100〜1000/100である請求項1記載の樹脂組成物。
- さらに、ヒンダードフェノール系酸化防止剤、リン系安定剤、フッ素系樹脂、及び充填剤から選択された少なくとも一種を含む請求項1記載の樹脂組成物。
- ベース樹脂(A)と、有機リン化合物(B)と、難燃助剤(C)とを混合して請求項1記載の難燃性樹脂組成物を製造する方法。
- 請求項1記載の難燃性樹脂組成物で形成された成形体。
- 電気・電子部品、オフィスオートメーション機器部品、家電機器部品、自動車部品、又は機械機構部品である請求項11記載の成形体。
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JPWO2004061008A1 (ja) | 2006-05-11 |
CN1324089C (zh) | 2007-07-04 |
WO2004061008A1 (ja) | 2004-07-22 |
US7411013B2 (en) | 2008-08-12 |
US20060074154A1 (en) | 2006-04-06 |
CN1732232A (zh) | 2006-02-08 |
AU2003292608A1 (en) | 2004-07-29 |
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