Mixtures of aluminum phosphite with sparingly soluble aluminum salts and foreign ions, process for the production thereof and the use thereof

Abstract

Mixtures of aluminum phosphite with sparingly soluble aluminum salts and extraneous ions, process for preparation thereof and use thereof The invention relates to mixtures of aluminum phosphite with sparingly soluble aluminum salts and nitrogen-free extraneous ions, comprising 80 to 99.898% by weight of aluminum phosphite of the formula (I) Al 2 (HPO 3 ) 3 xH 2 O  (I) in which x is 0 to 4, 0.1 to 10% by weight of sparingly soluble aluminum salts and 0.002 to 10% by weight of nitrogen-free extraneous ions; to a process for preparation thereof and use thereof.

1 .- 5 . (canceled) 
     
     
         6 . A process for preparing a mixture of aluminum phosphite with sparingly soluble aluminum salts and nitrogen-free extraneous ions, where the mixture of aluminum phosphite comprises: 
       80 to 99.898% by weight of an aluminum phosphite of the formula (I)
   Al 2 (HPO 3 ) 3 xH 2 O  (I)
 
 
       where x is 0 to 4; 
       0.1% to 10% by weight of the sparingly soluble aluminum salts; and 
       0.002 to 10% by weight of the nitrogen-free extraneous ions, 
       the process comprising crystallizing in a ratio of 2.5 to 3.5 mol of a non-salt phosphorus source with 2 mol of a sparingly soluble aluminum salt in the presence of an auxiliary acid at 50 to 180° C. in a solvent and at a solids concentration of 2 to 60%. 
     
     
         7 . The process as claimed in  claim 6 , wherein
 the sparingly soluble aluminum salts are selected from the group consisting of aluminum hydroxide, aluminum hydroxychloride, polyaluminum hydroxyl compounds, aluminum carbonates, hydrotalcites (Mg 6 Al 2 (OH) 16 CO 3 xnH 2 O), dihydroxyaluminum sodium carbonate (NaAl(OH) 2 CO 3 ), aluminum oxides, aluminum oxide hydrate, mixed aluminum oxide hydroxides, basic aluminum sulfate and alunite, and   the non-salt phosphorus source is selected from the group consisting of phosphorous acid, phosphorus trioxide, phosphorus trichloride and hypophosphite.   
     
     
         8 . The process as claimed in  claim 6 , wherein the auxiliary acid is selected from the group consisting of hydrochloric acid, hypochlorous acid, chlorous acid, chloric acid, hydrogen bromide, hydrofluoric acid, hydrogen iodide, periodic acid, perchloric acid, sulfuric acid, hydrogensulfate, sulfurous acid, hydrogensulfites, peroxosulfuric acid, peroxodisulfuric acid; nitric acid, nitrous acid, phosphoric acid, phosphorous acid, peroxophosphoric acid, hypophosphorous acid, carbonic acid, silicic acid, hexafluorosilicic acid, boric acid and carboxylic acids. 
     
     
         9 .- 10 . (canceled) 
     
     
         11 . A flame-retardant thermoplastic or thermoset polymer molding composition or polymer molding, film, filament or fiber comprising
 0.1 to 45% by weight of a mixture of aluminum phosphite with sparingly soluble aluminum salts and nitrogen-free extraneous ions;   55 to 99.9% by weight of thermoplastic or thermoset polymer or mixtures thereof;   0 to 55% by weight of additives; and   0 to 55% by weight of filler or reinforcing materials,   
       where the sum of the components is 100% by weight, and 
       wherein the mixture of aluminum phosphite with sparingly soluble aluminum salts and nitrogen-free extraneous ions comprises: 
       80 to 99.898% by weight of an aluminum phosphite of the formula (I)
   Al 2 (HPO 3 ) 3 xH 2 O  (I)
 
 
       where x is 0 to 4; 
       0.1 to 10% by weight of the sparingly soluble aluminum salts; and 
       0.002 to 10% by weight of the nitrogen-free extraneous ions. 
     
     
         12 . A flame-retardant thermoplastic or thermoset polymer molding composition or polymer molding, film, filament or fiber comprising
 0.1 to 45% by weight of a flame retardant mixture comprising 0.1 to 50% by weight of a mixture of aluminum phosphite with sparingly soluble aluminum salts and nitrogen-free extraneous ions;   50 to 99.9% by weight of a flame retardant, 55 to 99.9% by weight of a thermoplastic or thermoset polymer or mixtures thereof;   0 to 55% by weight of additives; and   0 to 55% by weight of filler or reinforcing materials,   
       where the sum of the components is 100% by weight, and 
       wherein the mixture of aluminum phosphite with sparingly soluble aluminum salts and nitrogen-free extraneous ions comprises: 
       80 to 99.898% by weight of an aluminum phosphite of the formula (I)
   Al 2 (HPO 3 ) 3 xH 2 O  (I)
 
 
       where x is 0 to 4; 
       0.1 to 10% by weight of the sparingly soluble aluminum salts; and 
       0.002 to 10% by weight of the nitrogen-free extraneous ions. 
     
     
         13 . The flame-retardant thermoplastic or thermoset polymer molding composition or polymer molding, film, filament or fiber as claimed in  claim 11 , wherein the flame retardant comprises
 dialkylphosphinic acids and/or salts thereof;   condensation products of melamine and/or reaction products of melamine with phosphoric acid and/or reaction products of condensation products of melamine with polyphosphoric acid or mixtures thereof;   nitrogen-containing phosphates of the formulae (NH 4 ) y H 3-y —PO 4  and (NH 4 —PO 3 ) z , where y is 1 to 3 and z is 1 to 10 000; and   benzoguanamine, tris(hydroxyethyl) isocyanurate, allantoin, glycoluril, melamine, melamine cyanurate, dicyandiamide and/or guanidine; magnesium oxide, calcium oxide, aluminum oxide, zinc oxide, manganese oxide, tin oxide, aluminum hydroxide, boehmite, dihydrotalcite, hydrocalumite, magnesium hydroxide, calcium hydroxide, zinc hydroxide, tin oxide hydrate, manganese hydroxide, zinc borate, basic zinc silicate and/or zinc stannate.   
     
     
         14 . The flame-retardant thermoplastic or thermoset polymer molding composition or polymer molding, film, filament or fiber as claimed in  claim 11 , wherein the flame retardant comprises melam, melem, melon, dimelamine pyrophosphate, melamine polyphosphate, melam polyphosphate, melon polyphosphate and/or melem polyphosphate and/or mixed poly salts thereof and/or ammonium hydrogenphosphate, ammonium dihydrogenphosphate and/or ammonium polyphosphate. 
     
     
         15 . The flame-retardant thermoplastic or thermoset polymer molding composition or polymer molding, film, filament or fiber as claimed in  claim 11 , wherein the flame retardant comprises aluminum hypophosphite, zinc hypophosphite, calcium hypophosphite, sodium phosphite, monophenylphosphinic acid and salts thereof, mixtures of dialkylphosphinic acids and salts thereof and monoalkylphosphinic acids and salts thereof, 2-carboxyethylalkylphosphinic acid and salts thereof, 2-carboxyethylmethylphosphinic acid and salts thereof, 2-carboxyethylarylphosphinic acid and salts thereof, 2-carboxyethylphenylphosphinic acid and salts thereof, oxa-10-phosphaphenanthrene (DOPO) and salts thereof and adducts onto para-benzoquinone, or itaconic acid and salts thereof. 
     
     
         16 . The flame-retardant thermoplastic or thermoset polymer molding composition or polymer molding, film, filament or fiber as claimed in  claim 12 , wherein the flame retardant comprises
 dialkylphosphinic acids and/or salts thereof;   condensation products of melamine and/or reaction products of melamine with phosphoric acid and/or reaction products of condensation products of melamine with polyphosphoric acid or mixtures thereof;   nitrogen-containing phosphates of the formulae (NH 4 ) y H 3-y PO 4  and (NH 4 PO 3 ) z , where y is 1 to 3 and z is 1 to 10 000; and   benzoguanamine, tris(hydroxyethyl) isocyanurate, allantoin, glycoluril, melamine, melamine cyanurate, dicyandiamide and/or guanidine; magnesium oxide, calcium oxide, aluminum oxide, zinc oxide, manganese oxide, tin oxide, aluminum hydroxide, boehmite, dihydrotalcite, hydrocalumite, magnesium hydroxide, calcium hydroxide, zinc hydroxide, tin oxide hydrate, manganese hydroxide, zinc borate, basic zinc silicate and/or zinc stannate.   
     
     
         17 . The flame-retardant thermoplastic or thermoset polymer molding composition or polymer molding, film, filament or fiber as claimed in  claim 12 , wherein the flame retardant comprises melam, melem, melon, dimelamine pyrophosphate, melamine polyphosphate, melam polyphosphate, melon polyphosphate and/or melem polyphosphate and/or mixed poly salts thereof and/or ammonium hydrogenphosphate, ammonium dihydrogenphosphate and/or ammonium polyphosphate. 
     
     
         18 . The flame-retardant thermoplastic or thermoset polymer molding composition or polymer molding, film, filament or fiber as claimed in  claim 12 , wherein the flame retardant comprises aluminum hypophosphite, zinc hypophosphite, calcium hypophosphite, sodium phosphite, monophenylphosphinic acid and salts thereof, mixtures of dialkylphosphinic acids and salts thereof and monoalkylphosphinic acids and salts thereof, 2-carboxyethylalkylphosphinic acid and salts thereof, 2-carboxyethylmethylphosphinic acid and salts thereof, 2-carboxyethylarylphosphinic acid and salts thereof, 2-carboxyethylphenylphosphinic acid and salts thereof, oxa-10-phosphaphenanthrene (DOPO) and salts thereof and adducts onto para-benzoquinone, or itaconic acid and salts thereof.