Flame retardant compositions with a phosphorated compound
View Patent ↗Flame retardant compositions that are halogen-free or substantially halogen-free are disclosed. In certain examples, the compositions comprise a halogen-free or substantially halogen-free epoxide and one or more phosphorated compounds. In some examples, the phosphorated compound comprises an average particle size less than 10 microns. In other examples, the phosphorated compound provides a surface area of 78.5 μm 2 to about 1965 μm 2 . Prepregs, laminates, molded articles and printed circuit boards using the compositions are also disclosed.
1. A substantially halogen-free flame retardant composition consisting essentially of:
a substantially halogen-free epoxide;
a polyphenylene ether; and
an effective amount of a phosphorated compound to provide flame retardancy, in which the phosphorated compound has an average particle size less than 10 microns,
wherein the substantially halogen-free flame retardant composition has a flame retardancy of V-0 as defined by the UL-94 burn test.
2. The composition of claim 1 further comprising about 40% to about 90% by weight of the substantially halogen-free epoxide.
3. The composition of claim 2 further comprising about 5% to about 30% by weight of the phosphorated compound.
4. The composition of claim 1 in which the phosphorated compound comprises particles with a surface area of at least about 78.5 μm 2 to about 1965 μm 2 .
5. The composition of claim 1 in which the phosphorated compound provides a flame retardant amount of chemically combined phosphorous that is about 3% to about 6% phosphorous by weight based on the weight of the composition.
6. The composition of claim 1 in which the phosphorated compound has a formula of
in which R 1 , R 2 and R 3 each is independently selected from the group consisting of alkyl, aryl, and alicyclic and heterocyclic groups that include nitrogen, oxygen and/or phosphorous.
7. The composition of claim 1 in which the phosphorated compound is an organic phosphate.
8. The composition of claim 1 , in which the polyphenylene ether is present from about 30% to about 80% by weight.
9. The composition of claim 1 further comprising at least one co-flame retardant.
10. The composition of claim 1 further comprising a catalyst selected from the group consisting of imidazole, 1-methylimidazole, 1,2-dimethylimidazole, 2-methylimidazole, 2-heptadecylimidazole, 2-ethyl-4-methylimidazole, 2-undecylimidazole, 1-(2-cyanoethyl)-2-phenylimidazole, diethyltoluenediamine, tris(dimethylaminomethyl)-phenol, 3-phenyl-1,1-dimethyl urea and mixtures thereof.
11. The composition of claim 1 in which the epoxide is a polyepoxide.
12. The composition of claim 11 in which the polyepoxide is a difunctional epoxide, a tetrafunctional epoxide, or an aromatic multi-functional epoxide.
13. The composition of claim 1 having a glass transition temperature of at least about 120° C.
14. The composition of claim 1 having a peel strength of at least about 4 lb/inch width as tested by IPC-TM-650 2.4.8C.
15. The composition of claim 1 having a dielectric constant at 1 MHz (50% weight resin) of less than about 5.0 as tested by IPC-TM-650 2.5.5.3C.
16. The composition of claim 1 having a dielectric dissipation factor at 1 MHz (50% resin content) of about 0.035 or less as tested by IPC-TM-650 2.5.5.3C.
17. A substantially halogen-free composition consisting essentially of:
a flame retardant amount of chemically combined phosphorous from a phosphorated compound having an average particle size of less than 10 microns;
a polyphenylene ether; and
a substantially halogen-free epoxide,
wherein the substantially halogen-free composition has a flame retardancy of V-0 as defined by the UL-94 burn test.
18. The substantially halogen-free composition of claim 17 further comprising a co-flame retardant.
19. The substantially halogen-free composition of claim 18 in which the amount of the epoxide is about 40% to about 90% by weight and the amount of the phosphorated compound is about 5% to about 30% by weight.
20. A substantially halogen-free composition consisting essentially of:
a flame retardant amount of chemically combined phosphorous from phosphorated particles having an average particle size less than 10 microns and providing a surface area of at least about 78.5 μm 2 to about 1965 μm 2 ;
a polyphenylene ether; and
a substantially halogen-free epoxide,
wherein the substantially halogen-free composition has a flame retardancy of V-0 as defined by the UL-94 burn test.
21. The substantially halogen-free composition of claim 20 further comprising a co-flame retardant.
22. The substantially halogen-free composition of claim 21 in which the amount of the epoxide is about 50% to about 90% by weight and the amount of the phosphorated compound is about 5% to about 30% by weight.
23. A substantially halogen-free flame retardant composition consisting essentially of:
a substantially halogen-free epoxide;
a polyphenylene ether;
an effective amount of a phosphorated compound to provide flame retardancy, in which the phosphorated compound has an average particle size less than 10 microns and has a surface area of at least about 78.5 μm 2 to about 1965 μm 2 ; and
a co-flame retardant,
in which the composition has a flame retardancy of V-0 as defined by the UL-94 burn test, a peel strength of at least about 4 lb/inch width as tested by IPC-TM-650 2.4.8C, a dielectric constant at 1 MHz (50% weight resin) of less than about 5.0 as tested by IPC-TM-650 2.5.5.3C, and a dielectric dissipation factor at 1 MHz (50% resin content) of about 0.035 or less as tested by IPC-TM-650 2.5.5.3C.