Flame retardant resin composition comprising an acrylonitrile-styrene base terpolymer, a different acrylonitrile-styrene-chlorinated polyethylene terpolymer and antimony trioxide

Claim 2

A resin composition having high flame retardancy, excellent impact strength, and good moldability or workability comprising:

Claim 3

10 ˜ 90 percent by weight of a first component comprising one or more ternary resin systems selected from the group consisting of a ternary resin comprising acrylonitrile, butadiene and styrene; a ternary resin of acrylonitrile, acrylic rubber and styrene; a ternary resin of acrylonitrile, an ethylene-propylene rubber and styrene; and a ternary resin of acrylonitrile, ethylene-vinyl acetate copolymer and styrene wherein the butadiene rubber component, acrylic rubber component, ethylene-propylene rubber component, ethylene-vinyl acetate copolymer component or mixture thereof comprisesd 10 ˜ 95 percent of the first component ternary resin system and the weight ratio of acrylonitrile to styrene is 1˜50/99˜50; 2. 90 ˜ 10 percent by weight of a second component comprising a ternary resin of acrylonitrile, chlorinated polyethylene and styrene, wherein the weight ratio of acrylonitrile to styrene is 1˜50/99˜50, containing 10 ˜ 95 percent by weight chlorinated polyethylene having a chlorination degreee of 25 ˜ 45 percent by weight, the content of said chlorinated polyethylene component in the whole resin composition being 5 ˜ 40 percent by weight and the total amount of said chlorinated polyethylene component and at least one of the members selected from the group consisting of the butadiene rubber component, the acrylic rubber component, the ethylene-propylene rubber component, and the ethylene-vinyl acetate copolymer component in said ternary resins (1) being not over 50 percent by weight of the resin composition; and 3. 2 ˜ 15 PHR of antimony trioxide based on 100 parts by weight of the resin composition, wherein all or part of the acrylonitrile can be replaced by methyl methacrylate and all or part of the styrene can be replaced by α-methylstyrene.

Claim 4

10 ˜ 90 percent by weight of a first component comprising one or more ternary resin systems selected from the group consisting of a ternary resin comprising acrylonitrile, butadiene and styrene; a ternary resin of acrylonitrile, acrylic rubber and styrene; a ternary resin of acrylonitrile, an ethylene-propylene rubber and styrene; and a ternary resin of acrylonitrile, ethylene-vinyl acetate copolymer and styrene wherein the butadiene rubber component, acrylic rubber component, ethylene-propylene rubber component, ethylene-vinyl acetate copolymer component or mixture thereof comprisesd 10 ˜ 95 percent of the first component ternary resin system and the weight ratio of acrylonitrile to styrene is 1˜50/99˜50; 2. 90 ˜ 10 percent by weight of a second component comprising a ternary resin of acrylonitrile, chlorinated polyethylene and styrene, wherein the weight ratio of acrylonitrile to styrene is 1˜50/99˜50, containing 10 ˜ 95 percent by weight chlorinated polyethylene having a chlorination degreee of 25 ˜ 45 percent by weight, the content of said chlorinated polyethylene component in the whole resin composition being 5 ˜ 40 percent by weight and the total amount of said chlorinated polyethylene component and at least one of the members selected from the group consisting of the butadiene rubber component, the acrylic rubber component, the ethylene-propylene rubber component, and the ethylene-vinyl acetate copolymer component in said ternary resins (1) being not over 50 percent by weight of the resin composition; and 3. 2 ˜ 15 PHR of antimony trioxide based on 100 parts by weight of the resin composition, wherein all or part of the acrylonitrile can be replaced by methyl methacrylate and all or part of the styrene can be replaced by α-methylstyrene.

Claim 5

The resin composition as claimed in claim 1 wherein said resin composition further contains 5 ˜ 65 PHR of polyvinyl chloride as a secondary flame retardant.

Claim 6

The resin composition as claimed in claim 1 wherein said resin composition further contains 2 ˜ 20 PHR of an organohalogen compound as a secondary flame retardant.

Claim 7

The resin composition as claimed in claim 1 wherein said resin composition further contains 2 ˜ 20 PHR of a halogenated phosphate ester as a secondary flame retardant.

Claim 8

The resin composition as claimed in claim 1 wherein said resin composition has a combustion rate of less than 3 cm/min.

Claim 9

The resin composition as claimed in claim 1 wherein the first component ternary resin comprises a member selected from the group consisting of: a. a graft copolymer of acrylonitrile or styrene onto the member selected from the group consisting of the butadiene rubber component, acrylic rubber component, ethylene-propylene rubber component, ethylene-vinyl acetate copolymer and a mixture thereof; b. a copolymer:copolymer mixture of a graft copolymer as in (a) plus an acrylonitrile-styrene copolymer; and c. a rubbery component:copolymer mixture of the member selected from the group consisting of the butadiene rubber component, acrylic rubber component, ethylene-propylene rubber component, ethylene-vinyl acetate copolymer component and the mixture thereof with an acrylonitrile-styrene copolymer; wherein all or part of the acrylonitrile can be replaced by methyl methacrylate and all or part of the styrene can be replaced by α-methylstyrene.

Claim 10

The resin composition as claimed in claim 6 wherein the member selected from the group consisting of the acrylonitrile-styrene copolymer wherein all or part of the acrylonitrile can be replaced by methyl methacrylate and all or part of the styrene can be replaced by α-methylstyrene exhibits an [η] value in chloroform at 30° C of from about 0.5 to about 2.0.

Claim 11

The resin composition as claimed in claim 6 wherein the first component ternary resin system is a graft copolymer of the recited components onto the rubbery component wherein the ratio of acrylonitrile to styrene or α-methylstyrene is 1˜50/99˜50 by weight percent and the ratio of methyl methacrylate to styrene is 1˜80/99˜20 by weight percent, acrylonitrile/methyl methacrylate systems having a permissible maximum weight percent in the 50 ˜ 80 weight percent range.

Claim 12

The resin composition as claimed in claim 7 wherein the the first component ternary resin system comprises a graft copolymer of the recited components blended with an acrylonitrile-styrene copolymer wherein the ratio of acrylonitrile to styrene or α-methylstyrene is 1˜50/99˜50 by weight percent and the ratio of methyl methacrylate to styrene is 1˜80/99˜20 by weight percent, acrylonitrile/methyl methacrylate systems having a permissible maximum weight percent in the 50 ˜ 80 weight percent range.

Claim 13

The resin composition as claimed in claim 7 wherein the first component comprises a blend of at least one of the members selected from the group consisting of the butadiene rubber component, the acrylic rubber component, the ethylene-propylene rubber component and the ethylene-vinyl acetate copolymer component with an arcylonitrile-styrene copolymer, wherein the ratio of acrylonitrile to styrene or α-methylstyrene is 1˜50/99˜50 by weight percent and the ratio of methyl methacrylate to styrene is 1˜80/99˜20 by weight percent, acrylonitrile/methyl methacrylate systems having a permissible maximum weight percent in the 50 ˜ 80 weight percent range.

Claim 14

The resin composition as claimed in claim 6 where the rubber component is at least in part the butadiene rubber component, which is polybutadiene having a Mooney viscosity ML 1 +4 of about 30 to about 55 or a styrene-butadiene rubber comprising less than 85 weight percent styrene and having a Mooney viscosity of about 20 to about 165, and: for the graft copolymer (a) or the copolymer mixture (b), acrylonitrile and styrene are grafted onto said rubbery component, wherein all or part of the acrylonitrile can be replaced by methyl methacrylate and all or part of the styrene can be replaced by α-methylstyrene, and wherein the ratio of acrylonitrile to styrene or α-methylstyrene is 1-50/99-50 by weight percent and the ratio of methyl methacrylate to styrene is 1-80/99-20 by weight percent, acrylonitrile/methyl methacrylate systems having a permissible maximum weight percent in the 50 - 80 weight percent range; and for the copolymer: copolymer mixture (b) or the rubbery component: copolymer mixture (c) the graft copolymer is the same as above and the acrylonitrile-styrene copolymer and/or methyl methacrylate and/or α-methylstyrene substituted form thereof exhibits an [η] value in chloroform at 30° C of from about 0.5 to about 2.0.

Claim 15

The resin composition as claimed in claim 6 where the rubbery component is at least in part the acrylic rubber component, which has a nitrogen content of about 15 to about 60 weight percent and a Mooney viscosity ML 1+4 of about 30 to about 130, and for the graft copolymer (a) or the copolymer mixture(b), acrylonitrile and styrene are grafted onto said rubbery component, wherein all or part of the acrylonitrile can be replaced by methyl methacrylate and all or part of the styrene can be replaced by α-methylstyrene, and wherein the ratio of acrylonitrile to styrene or α-methylstyrene is 1-50/99-50 by weight percent and the ratio of methyl methacrylate to styrene is 1-80/99-20 by weight percent, acrylonitrile/methyl methacrylate systems having aa permissible maximum weight percent in the 50-80 weight percent range; and for the copolymer: copolymer mixture (b) or the rubbery component: copolymer mixture (c) the graft copolymer is the same as above and the acrylonitrile-styrene copolymer and/or methyl methacrylate and/or α-methylstyrene substituted form thereof exhibits an [η] value in chloroform at 30° C of from about 0.5 to about 2.0.

Claim 16

The resin composition as claimed in claim 6 where the rubbery component is at least in part the ethylene-propylene rubber component, wherein the ethylene-propylene rubber has a density of from about 0.85 to about 0.87 and a Mooney viscosity ML 1 +4 of from about 30 to about 120, and for the graft copolymer (a) or the copolymer mixture (b), acrylonitrile and styrene are grafted onto said rubbery component, wherein all or part of the arcylonitrile can be repplaced by methyl methacrylate and all or part of the styrene can be replaced by α-methylstyrene, and wherein the ratio of acrylonitrile to styrene or α-methylstyrene is 1-50/99-50 by weight percent and the ratio of methyl methacrylate to styrene is 1˜80/00˜20 by weight percent, acrylonitrile/methyl methacrylate systems having a permissible maximum weight percent in the 50 ˜ 80 weight percent range; and for the copolymer:copolymer mixture (b) or the rubbery component:copolymer mixture(c) the graft copolymer is the same as above and the acrylonitrile-styrene copolymer and/or methyl methacrylate and/or α-methylstyrene substituted form thereof exhibits an [η] value in chloroform at 30° C of from about 0.5 to about 2.0.

Claim 17

The resin composition as claimed in claim 13 wherein the ethylene-propylene rubber component is an ethylene-propylene copolymer or an ethylene-propylene-unconjugated diene terpolymer, the proportion of ethylene to propylene being from about 35 to about 85 weight percent ethylene and about 65 to about 15 weight percent propylene, and in the unconjugated diene containing terpolymer in an amount of on the order of 3 weight percent, based on ethylene plus propylene.

Claim 18

The resin composition as claimed in claim 6 where the rubbery component is at least in part the ethylene-vinyl acetate copolymer component, wherein the ethylene-vinyl acetate copolymer component has a molecular weight of from about 20,000 to about 200,000 and is 10 ˜ 95 weight percent vinyl acetate, balance ethylene, and for the graft copolymer (a) or the copolymer mixture (b), acrylonitrile and styrene are grafted onto said rubbery component, wherein all or part of the acrylonitrile can be replaced by methyl methacrylate and all or part of the styrene can be replaced by α-methylstyrene, and wherein the ratio of acrylonitrile to styrene or α-methylstyrene is 1-50/99-50 by weight percent and the ratio of methyl methacrylate to styrene is 1-80/99-20 by weight percent, acrylonitrile/methyl methacrylate systems having a permissible maximum weight percent in the 50-80 weight percent range; and for the copolymer: copolymer mixture (b) or the rubbery component: copolymer mixture (c) the graft copolymer is the same as above and the acrylonitrile-styrene copolymer and/or methyl methacrylate and/or α-methylstyrene substituted form thereof exhibits an [η] value in chloroform at 30° C of from about 0.5 to about 2.0.

Claim 19

The resin composition as claimed in claim 6 where the rubbery component is at least in part the acrylic rubbe component, wherein the ternary resin is a ternary resin of acrylonitrile, acrylic rubber and styrene, the acrylic rubber comprising a copolymer of an acrylic acid alkyl ester present in an amount of at least 65 weight percent of the copolymer, and for the graft copolymer (a) or the copolymer mixture (b), acrylonitrile and styrene are grafted onto said rubbery component, component, wherein all or part of the acrylonitrile can be replaced by methyl methacrylate and all or part of the styrene can be replaced by α-methylstyrene, and wherein the ratio of acrylonitrile to styrene or α-methylstyrene is 1˜50/99˜50 by weight percent and the ratio of methyl methacrylate to styrene is 1˜80/99˜20 by weight percent, acrylonitrile/methyl methacrylate systems having a permissible maximum weight percent in the 50 ˜ 80 weight percent range; and for the copolymer: copolymer mixture (b) or the rubbery component: copolymer mixture (c) the graft copolymer is the same as above and the acrylonitrile-styrene copolymer and/or methyl methacrylate and/or α-methylstyrene substituted form thereof exhibits an [η] value in chloroform at 30° C of from about 0.5 to about 2.0.

Claim 20

The resin composition as claimed in claim 16 wherein the acrylic acid alkyl ester is copolymerized with acrylonitrile or 2-chloroethyl vinyl ether.

Claim 21

The resin composition as claimed in claim 1 wherein the antimony trioxide comprises 3 ˜ 8 PHR of the resin composition.

Claim 22

The resin composition as claimed in claim 1 wherein the antimony trioxide has an average particle size of from about 1 micron to about 4 microns.