US 12,286,520 B2
Flame retardant masterbatch composition for foams containing a pH moderator
Wenyi Huang, Midland, MI (US); Shari Kram, Sanford, MI (US); Mark Rickard, Midland, MI (US); and Ravi B Shankar, Midland, MI (US)
Assigned to DDP SPECIALTY ELECTRONIC MATERIALS US, LLC, Wilmington, DE (US)
Filed by DDP Specialty Electronic Materials US, LLC, Wilmington, DE (US)
Filed on Feb. 7, 2024, as Appl. No. 18/435,138.
Application 18/435,138 is a division of application No. 17/516,016, filed on Nov. 1, 2021, granted, now 11,939,445.
Claims priority of provisional application 63/119,883, filed on Dec. 1, 2020.
Prior Publication US 2024/0174828 A1, May 30, 2024
Int. Cl. C08J 3/22 (2006.01); C08J 3/20 (2006.01); C08J 9/00 (2006.01); C08J 9/12 (2006.01); C08J 9/14 (2006.01); C08L 25/06 (2006.01)
CPC C08J 9/0061 (2013.01) [C08J 3/201 (2013.01); C08J 3/226 (2013.01); C08J 9/0095 (2013.01); C08J 9/122 (2013.01); C08J 9/125 (2013.01); C08J 9/146 (2013.01); C08L 25/06 (2013.01); C08J 2201/03 (2013.01); C08J 2203/06 (2013.01); C08J 2203/10 (2013.01); C08J 2203/142 (2013.01); C08J 2363/04 (2013.01); C08J 2425/06 (2013.01); C08L 2201/02 (2013.01); C08L 2203/14 (2013.01)] 6 Claims
 
1. A process for manufacturing a masterbatch composition suitable for use as a flame retardant in extruded polymer foams, comprising the steps of:
a) providing a base resin to a mixing device operating at temperature of 150 to 230° C. to form a molten base resin;
b) contacting the molten base resin in the mixing device with:
i) acid scavenger comprising an epoxy-based compound;
ii) antioxidant comprising an alkyl or aryl phosphite;
iii) water soluble pH moderator; and
iv) flame retardant comprising a non-hexabromocyclododecane (HBCD) polymer or copolymer
 to form a molten flame retardant masterbatch composition; and
c) cooling the molten flame retardant masterbatch composition to form a solid flame retardant masterbatch composition,
wherein the masterbatch composition has
(A) 20 to 40 parts by weight of the base resin comprising styrene homopolymer or copolymer;
(B) 1 to 16 parts by weight of the acid scavenger comprising an epoxy-based compound;
(C) 2 to 6 parts by weight of the antioxidant comprising an alkyl or aryl phosphite; and
(D) 45 to 60 parts by weight of the flame retardant comprising a non-hexabromocyclododecane (HBCD) brominated polymer or copolymer;
wherein the amounts of (A), (B), (C), and (D) total 100 parts by weight; and
(E) 0.6 to 10 parts by weight of the water soluble pH moderator, based on 100 parts of (A) base resin plus (E) water soluble pH moderator.