Phosphonate polymers, copolymers, and their respective oligomers as flame retardants for polyamide fibers

Abstract

The invention relates to the use of polyphosphonates, copoly(phosphonate ester)s, copoly(phosphonate carbonate)s, and their respective oligomers, as flame retardant additives for polyamide fibers to impart fire resistance while maintaining or improving processing characteristics for melt spun fibers and fabrics, thereof.

1 . A polymer fiber comprising: a thermoplastic polyamide; and at least one phosphonate containing polymer, copolymer, oligomer, or combination thereof. 
     
     
         2 . The polymer fiber of  claim 1 , wherein the thermoplastic polyamide comprises nylon 6, nylon 6-6, nylon 6-10, nylon 11, nylon 12, nylon 4-6, nylon 6-12, nylon 6-6T, nylon 6T, nylon 6I-6T, MXD6, or any combination of these. 
     
     
         3 . The polymer fiber of  claim 1 , wherein the phosphonate containing polymer, copolymer, oligomer, or combination thereof comprises at least one polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate), oligomeric phosphonates oligomeric cophosphonate esters, oligomeric cophosphonate carbonates, and combinations thereof. 
     
     
         4 . The polymer fiber of  claim 1 , wherein the phosphonate containing polymer, copolymer, oligomer, or combination thereof comprises repeating units derived from diaryl alkylphosphonate, diaryl arylphosphonate, and combinations thereof, and diphenyl methylphosphonate and aromatic dihydroxy compound. 
     
     
         5 . The polymer fiber of  claim 1 , wherein the phosphonate containing polymer, copolymer, oligomer or combination thereof comprises at least one polyphosphonate, copoly(phosphonate ester), or copoly(phosphonate carbonate) having a molecular weight of from about 10,000 g/mole to about 120,000 g/mole measured against PS standards. 
     
     
         6 . The polymer fiber of  claim 1 , wherein the phosphonate containing polymer, copolymer, oligomer or combination thereof comprises at least one oligomeric phosphonate, oligomeric cophosphonate ester, or oligomeric cophosphonate carbonate having a molecular weight of from about 1,000 g/mole to about 10,000 g/mole. 
     
     
         7 . The polymer fiber of  claim 1 , wherein the polymer fiber comprises about 1 wt. % to about 25 wt. % of the at least one phosphonate containing polymer, copolymer, oligomer, or combination thereof. 
     
     
         8 . The polymer fiber of  claim 1 , further comprising one or more fire resistant additives, fillers, delusterants, dyes, antioxidants, viscosity modifiers, pigments, anti-dripping agents, lubricants, wetting agents, anti-microbials, or combinations thereof. 
     
     
         9 . The polymer fiber of  claim 1 , wherein the polymer fiber comprises a fiber diameter of from about 2 μm to about 60 μm. 
     
     
         10 . The polymer fiber of  claim 1 , wherein the polymer fiber comprises a fiber denier of from about 0.9 denier to about 30 denier. 
     
     
         11 . The polymer fiber of  claim 1 , wherein the polymer fiber exhibits a limiting oxygen index (LOI) of at least 27. 
     
     
         12 . The polymer fiber of  claim 1 , wherein the material from which the polymer fiber was made exhibits an Underwriters Laboratory-94 (UL-94) of V-0 measured at a thickness of 0.8 mm. 
     
     
         13 . An article of manufacture employing the polymer fiber of  claim 1 , wherein the article of manufacture comprises fire retarding clothing, military or police equipment, carpet, flooring materials, wigs, and non-woven articles. 
     
     
         14 . The article of manufacture of  claim 13 , wherein the article of manufacture comprises flame retarding bottles, films, tarpaulin, filters, dielectric films, insulation for wires, insulating tapes, moldings, shirts, pants, jackets, hats, bed sheets, upholstered furniture, tapestries, wall coverings, curtains, insulating material, pillows, blankets, quilts, comforters, luggage, ropes, tire reinforcements, fabrics for conveyor belts, tires, safety belts, coated fabrics, or plastic reinforcements with high-energy absorption upholstery padding. 
     
     
         15 . A fabric comprising fibers of  claim 1 . 
     
     
         16 . A yarn comprising the fibers of  claim 1 . 
     
     
         17 . A staple fiber comprising the fibers of  claim 1 . 
     
     
         18 . A garment made from the fabric of  claim 15 . 
     
     
         19 . A fabric of  claim 15  which self-extinguishes in an ASTM D6413 vertical flammability test.