Thermoplastic Resin Composition and Molded Product Manufactured Therefrom

Abstract

A thermoplastic resin composition of the present invention comprises: approximately 100 parts by weight of an ethylene-propylene block copolymer; approximately 0.3-5 parts by weight of metal phosphinate compound; approximately 0.5-5 parts by weight of a phosphorus-nitrogen-based retardant; and approximately 0.01-0.2 parts by weight of a bromine-based retardant. The thermoplastic resin composition has excellent flame retardancy, impact resistance, and the like.

Claims

1. A thermoplastic resin composition comprising: about 100 parts by weight of an ethylene-propylene block copolymer; about 0.3 parts by weight to about 5 parts by weight of a metal phosphinate compound; about 0.5 parts by weight to about 5 parts by weight of a phosphorus nitrogen-based flame retardant; and about 0.01 parts by weight to about 0.2 parts by weight of a bromine-based flame retardant.

2. The thermoplastic resin composition according to claim 1, wherein the ethylene-propylene block copolymer comprises about 20% wt % to about 60 wt % of ethylene and about 40 wt % to about 80 wt % of propylene.

3. The thermoplastic resin composition according to claim 1, wherein the ethylene-propylene block copolymer comprises about 60 wt % to about 95 wt % of a propylene homopolymer and about 5 wt % to about 40 wt % of a rubbery ethylene-propylene copolymer.

4. The thermoplastic resin composition according claim 1, wherein the ethylene-propylene block copolymer has a melt-flow index (MI) of about 5 g/10 min to about 100 g/10 min, as measured under conditions of 230° C. and 2.16 kgf in accordance with ASTM D1238.

5. The thermoplastic resin composition according to claim 1, wherein the metal phosphinate compound is represented by Formula 1: ##STR00003## wherein R.sub.1 and R.sub.2 are each independently a C.sub.1 to C.sub.6 alkyl group or a C.sub.6 to C.sub.12 aryl group; M is Al, Zn, Mg, Ca, Sb, Sn, Ge, Ti, Fe, Zr, Ce, Bi, Sr, Mn, Li, or Na; and n is an integer of 1 to 4.

6. The thermoplastic resin composition according to claim 1, wherein the phosphorus nitrogen-based flame retardant comprises melamine polyphosphate, melam pyrophosphate, melem pyrophosphate, melon pyrophosphate, melamine pyrophosphate, dimelamine pyrophosphate, melamine polyphosphate, melam polyphosphate, melon polyphosphate, melem polyphosphate, mixed multi-salts thereof, ammonium hydrogen phosphate, ammonium dihydrogen phosphate, and/or ammonium polyphosphate.

7. The thermoplastic resin composition according to claim 1, wherein the bromine-based flame retardant comprises tetrabromo bisphenol-A bis(2,3-dibromopropyl ether), tetrabromo bisphenol-A, decabromodiphenyl oxide, decabrominated diphenyl ethane, 1,2-bis(2,4,6-tribromophenyl)ethane, octabromo-1,3,3-trimethyl-1-phenylindane, and/or 2,4,6-tris(2,4,6-tribromophenoxy)-1,3,5-triazine.

8. The thermoplastic resin composition according to claim 1, wherein the metal phosphinate compound and the phosphorus nitrogen-based flame retardant are present in a weight ratio of about 1:0.2 to about 1:5.

9. The thermoplastic resin composition according to claim 1, wherein the metal phosphinate compound and the bromine-based flame retardant are present in a weight ratio of about 1:0.01 to about 1:0.6.

10. The thermoplastic resin composition according to claim 1, wherein the phosphorus nitrogen-based flame retardant and the bromine-based flame retardant are present in a weight ratio of about 1:0.01 to about 1:0.4.

11. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a flame retardancy of V-2, as measured on a 1.5 mm thick injection-molded specimen in accordance with a UL-94 vertical test method.

12. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a glow wire ignitability temperature (GWIT) of about 730° C. or more and a glow wire flammability index (GWFI) of about 870° C. or more, as measured on a specimen having a size of 100 mm×100 mm×1.5 mm in accordance with UL746A.

13. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a halogen content of about 100 ppm to about 900 ppm in a 15 mg specimen, as measured by ion chromatography in accordance with KS C IEC 62321-3-2.

14. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition has a notched Izod impact strength of about 7 kgf.Math.cm/cm to about 30 kgf.Math.cm/cm, as measured on a 6.4 mm thick specimen in accordance with ASTM D256.

15. A molded product produced from the thermoplastic resin composition according to claim 1.

Description

EXAMPLE

[0059] Details of components used in Examples and Comparative Examples are as follows.

[0060] (A) Thermoplastic Resin

[0061] (A1) Ethylene-propylene block copolymer (Manufacturer: Lotte Chemical Co., Ltd., Product Name: JH-370A, Melt-flow index (MI): 35 g/10 min)

[0062] (A2) Polypropylene resin (Manufacturer: Lotte Chemical Co., Ltd., Product Name: H1500, Melt-flow index (MI): 12 g/10 min)

[0063] (A3) Ethylene-propylene random copolymer (Manufacturer: Lotte Chemical Co., Ltd., Product Name: J-560S, Melt-flow index (MI): 20 g/10 min)

[0064] (B) Metal Phosphinate Compound

[0065] Aluminum diethyl phosphinate (Manufacturer: Clariant, Product Name: OP1230)

[0066] (C) Phosphorus Nitrogen-Based Flame Retardant

[0067] Melamine polyphosphate (Manufacturer: JLS, Product Name: PNA350)

[0068] (D) Bromine-Based Flame Retardant

[0069] Tetrabromo bisphenol-A bis(2,3-dibromopropyl ether) (Manufacturer: Suzuhiro Chemical, Product Name: FCP-680G)

[0070] (E) Phosphorus-Based Flame Retardant

[0071] Bisphenol-A diphosphate (Manufacturer: Daihachi, Product Name: CR-741)

Examples 1 to 7 and Comparative Examples 1 to 9

[0072] The above components were mixed in amounts as listed in Tables 1 and 2, and subjected to extrusion at 200° C., thereby preparing pellets. Here, extrusion was performed using a twin-screw extruder (L/D=36, Φ: 45 mm) and the prepared pellets were dried at 80° C. for 4 hours or more and injection-molded in a 6 oz. injection molding machine (molding temperature: 260° C., mold temperature: 60° C.), thereby preparing specimens. The specimens were evaluated as to the following properties by the following method, and results are shown in Tables 1 and 2.

[0073] Property Measurement

[0074] (1) Flame retardancy: Flame retardancy was measured on a 1.5 mm thick injection-molded specimen in accordance with the UL-94 vertical test method.

[0075] (2) Glow wire ignitability temperature (GWIT) (unit: ° C.): GWIT was measured on a specimen having a size of 100 mm×100 mm×1.5 mm in accordance with UL746A.

[0076] (3) Glow wire flammability index (GWFI) (unit: ° C.): GWFI was measured on a specimen having a size of 100 mm×100 mm×1.5 mm in accordance with UL746A.

[0077] (4) Halogen content (unit: ppm): Halogen content in a 15 mg specimen was measured by ion chromatography in accordance with KS C IEC 62321-3-2.

[0078] (5) Notched Izod impact strength (kgf.Math.cm/cm): Notched Izod impact strength was measured on a 6.4 mm thick specimen in accordance with ASTM D256.

TABLE-US-00001 TABLE 1 Example 1 2 3 4 5 6 7 (A1) (parts by weight) 100 100 100 100 100 100 100 (A2) (parts by weight) — — — — — — — (A3) (parts by weight) — — — — — — — (B) (parts by weight) 0.5 1 4 1 1.5 1 1 (C) (parts by weight) 2 2 1.5 1 4 1 2 (D) (parts by weight) 0.1 0.1 0.1 0.05 0.1 0.05 0.13 (E) (parts by weight) — — — — — — — Flame retardancy V-2 V-2 V-2 V-2 V-2 V-2 V-2 GWIT (° C.) 750 775 775 750 775 750 775 GWFI (° C.) 900 960 960 900 960 900 960 Halogen content (ppm) 650 650 630 330 630 330 845 Notched Izod impact 10 10 8 12 8 12 10 strength (kgf .Math. cm/cm)

TABLE-US-00002 TABLE 2 Comparative Example 1 2 3 4 5 6 7 8 9 (A1) (parts — — 100 100 100 100 100 100 100 by weight) (A2) (parts 100 — — — — — — — — by weight) (A3) (parts — 100 — — — — — — — by weight) (B) (parts 1 1 0.2 8 1 1 1 1 1 by weight) (C) (parts 2 2 2 2 0.2 8 2 2 — by weight) (D) (parts 0.1 0.1 0.1 0.1 0.1 0.1 — 1 0.1 by weight) (E) (parts — — — — — — — — 2 by weight) Flame V-2 Fail Fail V-2 Fail Fail Fail V-2 Fail retardancy GWIT 725 725 725 750 725 700 750 750 700 (° C.) GWFI 800 850 850 960 850 800 900 960 800 (° C.) Halogen 650 650 650 610 660 620 0 6,450 650 content (ppm) Notched 2 6 10 3 10 3 10 6 10 Izod impact strength (kgf .Math. cm/cm)

[0079] From the above results, it could be seen that the thermoplastic resin composition according to the present invention exhibited good properties in terms of flame retardancy (UL94, GWIT, GWFR) and impact resistance (notched Izod impact strength), and had a halogen content of 900 ppm or less satisfying the RoHS international environment regulation.

[0080] Conversely, it could be seen that the thermoplastic resin composition prepared using the polypropylene resin (A2) instead of the ethylene-propylene block copolymer (A1) (Comparative Example 1) suffered from deterioration in flame retardancy and impact resistance; and the thermoplastic resin composition prepared using the ethylene-propylene random copolymer (A3) instead of the ethylene-propylene block copolymer (A1) (Comparative Example 2) suffered from deterioration in flame retardancy and impact resistance. In addition, it could be seen that the thermoplastic resin composition prepared using an insufficient amount of the metal phosphinate compound (Comparative Example 3) suffered from deterioration in flame retardancy; the thermoplastic resin composition prepared using an excess of the metal phosphinate compound (Comparative Example 4) suffered from deterioration in impact resistance; the thermoplastic resin composition prepared using an insufficient amount of the phosphorus nitrogen-based flame retardant (Comparative Example 5) suffered from deterioration in flame retardancy; the thermoplastic resin composition prepared using an excess of the phosphorus nitrogen-based flame retardant (Comparative Example 6) suffered from deterioration in flame retardancy and impact resistance; the thermoplastic resin composition free from the bromine-based flame retardant (Comparative Example 7) suffered from deterioration in flame retardancy; and the thermoplastic resin composition prepared using an excess of the bromine-based flame retardant (Comparative Example 8) suffered from significant increase in halogen content and failed to satisfy the international environment regulation. Further, it could be seen that the thermoplastic resin composition prepared using the phosphorus flame retardant instead of the phosphorus nitrogen-based flame retardant (C) (Comparative Example 9) suffered from deterioration in flame retardancy and the like.

[0081] It should be understood that various modifications, changes, alterations, and equivalent embodiments can be made by those skilled in the art without departing from the spirit and scope of the present invention.