Polymer brominated flame retardant composition for use in wires and / or cables

Abstract

The present invention relates to flame retardant compositions and polymer-brominated flame retardant compositions for use in wires and / or cables. The brominated flame retardants contain aromatically linked bromine and, in some embodiments, are considered to be brominated styrene-based polymers. The brominated flame retardants have a weight-average molecular weight (Mw) of about 650 to about 75,000 and a bromine content of about 60% by weight or more. The present invention further relates to a process for forming a flame retardant composition, the process comprising: a first step, a second step, extruding the mixture from the first step to coat wires and / or cables; and a third step, exposing the mixture from the first step to either or both of a heating and / or external moisture to allow the product to reach a desired degree of crosslinking. The process comprises: a first step, a second step, extruding the mixture from the first step to coat wires and / or cables; and a third step, exposing the mixture from the first step to either or both of external moisture to allow the product to reach a desired degree of crosslinking.

Description

Technical Field

[0001] The present invention relates to a flame - retardant composition and a polymer brominated flame - retardant composition for use in wires and / or cables.

Background Art

[0002] Wire tubes, appliances, or wires and cables for automobiles often have only a single polymer layer. This layer must simultaneously perform multiple functions that are performed by individual layers in other low - voltage cables, medium - voltage cables, and high - voltage cables. Therefore, the polymer compositions used in the manufacture of wire tubes, appliances, or automotive wires must simultaneously meet requirements including excellent insulating properties, excellent mechanical properties, especially excellent abrasion resistance, excellent flame retardancy, excellent heat distortion resistance, cold resistance, resistance to water and chemicals, and excellent processing properties.

[0003] Many plastics, including polyolefins, are flame - retarded to suppress the spread of fire. In WO2005 / 095685 and WO2022 / 031932, polybrominated anionic styrenic polymers are used in combination with at least one synergist for flame - retarding polyolefins. WO 2001 / 029124 discloses polyolefins containing bis(2,3 - dibromopropyl ether) of tetrabromobisphenol A and bis(2,3 - dibromopropyl ether) of tetrabromobisphenol S as flame retardants. US Patent No. 6780348 discloses a combination of polybromodiphenylalkane and tetrabromobisphenol - A - bis(bromoalkyl ether). US Patent Nos. 8476373 and US Patent No. 8933159 are directed to brominated anion chain - transfer vinyl aromatic polymers that can flame - retard polyolefins.

[0004] Flame retardants are used in the formulation of wires and / or cables to achieve the fire resistance required for specific applications, such as household appliances, building and construction, automotive cables, and solar power wires. In these applications, flame retardancy is imparted by incorporating various flame retardant chemicals and technologies (bromine, phosphorus, metal hydroxides (e.g., magnesium hydroxide, aluminum hydroxide, etc.)) into the insulating coating of the conductor. Such flame retardant chemicals are also used in the formulation of the jacket (the layer on top of the insulating layer). The insulating layer or jacket may be (1) a thermoplastic material or (2) a thermosetting material (crosslinked).

[0005] Examples of thermoplastic materials used in insulating layers or jackets include, but are not limited to, polyurethane, polyester, polyamide, polyolefin, styrene polymers, chlorinated polyethylene, and combinations thereof.

[0006] Thermoplastic compounding for use in wires and / or cables is generally formed by crosslinking techniques, including (a) moisture curing, (b) peroxide curing, or (c) electron beam curing. Non-limiting examples of base polymers suitable for crosslinking include polyolefins such as polyethylene, polyolefin copolymers such as poly(ethylene-vinyl acetate) (EVA) and poly(ethylene-ethyl acrylate) (EEA), and polyolefin derivatives such as polyethylene chloride and silane-functionalized polyethylene.

[0007] Existing non-polymer brominated flame retardants (BFRs) often have melting points higher than processing conditions, and before being used in wire and / or cable formulations, they have an average particle size of approximately 10 microns. It needs to be ground to a very small, uniform particle size to achieve fullness. Larger particle sizes negatively affect the smoothness of the wire insulation surface. In addition to the expensive and / or time-consuming grinding process, non-polymer BFRs often generate high extrusion back pressure during kneading.

[0008] Therefore, there is a constant need in this field for improved flame-retardant compositions for use in wires and / or cables. [Overview of the Initiative]

[0009] The present invention provides flame-retardant compositions comprising thermoplastics for use in wires and / or cables. Non-limiting examples of thermoplastics include polyurethanes, polyesters, polyamides, polyolefins, styrene polymers, chlorinated polyethylene, and combinations thereof. The flame retardants are brominated polymer-based flame retardants. Polymer-based brominated flame retardants (PBFRs) are based on a polystyrene backbone and are synthesized by an aromatic bromination process. These PBFR formulations offer unique properties not possible with conventional brominated flame retardant technologies and are suitable for a variety of wire and / or cable applications.

[0010] Another embodiment of the present invention provides a flame retardant composition comprising a thermoplastic compound for use in wires and / or cables. Thermoplastic compound for wires and / or cables is generally formed by crosslinking techniques, including (a) moisture curing, (b) peroxide curing, or (c) electron beam curing techniques. Non-limiting examples of base polymers suitable for crosslinking include polyolefins such as polyethylene, polyolefin copolymers such as poly(ethylene-vinyl acetate) (EVA) and poly(ethylene-ethyl acrylate) (EEA), and polyolefin derivatives such as polyethylene chloride and silane-functionalized polyethylene. The flame retardant is a brominated polymer-based flame retardant. Polymer-based brominated flame retardants (PBFRs) are based on a polystyrene backbone and are synthesized by an aromatic bromination process. These PBFR compositions offer unique properties not possible with conventional brominated flame retardant techniques and are suitable for a variety of wire and / or cable applications.

[0011] Other embodiments of the present invention include flame-retardant compositions and processes for producing flame-retardant treated thermoplastic or thermosetting compositions of the present invention, as well as their use as coatings for wires and / or cables.

[0012] These and other embodiments and features of the present invention will become even more apparent from the following description and the appended claims. [Modes for carrying out the invention]

[0013] The brominated polymer flame retardants of the present invention offer numerous advantages. For example, existing non-polymer BFRs have a higher melting temperature than the process conditions allow. Therefore, non-polymer BFRs need to be ground to a very small and uniform particle size (less than approximately 10 microns on average) before being used in wire and / or cable compositions. However, the polymer flame retardants of the present invention have a lower glass transition temperature (Tg) than the processing temperature of typical wires and / or cables (Tg is less than approximately 145°C, compared to a processing temperature of approximately 200°C). Therefore, at the processing temperature, polymer BFRs can be easily melted and mixed and blended with other components of the composition.

[0014] Furthermore, unlike existing polymer BFRs and non-polymer BFRs, the novel polymer BFR formulations of the present invention, due to their high solubility index, are extruded during the formulation and wire extrusion processes. Lower back pressure (a higher melting index means better polymer flow at a given pressure and temperature) allows compounders and wire manufacturers to perform extrusion at higher throughput (pounds per hour or meters per hour).

[0015] Unlike conventionally disclosed polymer-based brominated flame retardants (BFRs), the polymer-brominated flame retardants of the present invention offer higher thermal stability. While polymer-based BFRs used in wire and / or cable applications in other inventions are often aliphatic brominated polymers, the polymer-based BFRs of the present invention have bromine bonded to aromatic rings. Aromatic bromine has higher thermal stability than aliphatic bromine. Higher thermal stability means that (a) the composition can be used at higher processing temperatures, (b) the operating time during wire coating can be extended, and (c) improved recyclability can be expected.

[0016] Furthermore, the polymer brominated flame retardant of the present invention enables a simple moisture-curing composition that passes the VW-1 flame retardancy test for wires and cables according to the UL-44 standard. To achieve a moisture-curing composition that passes the VW-1 test, compounders typically mix in about 5% zinc oxide (ZnO) or other zinc salts in addition to BFR and antimony trioxide (ATO), a common flame retardant synergist. The new polymer-based BFR of the present invention makes it possible to produce a moisture-curing composition that passes the VW-1 test without using ZnO or other zinc salts. By removing ZnO and other zinc salts from the composition, it becomes possible to make the composition compatible with more efficient silanol catalysts. This allows wire manufacturers to adopt curing conditions at ambient temperature (low temperature). Otherwise, it is necessary to use expensive sauna curing facilities. In addition, removing ZnO and other zinc salts reduces the density of the composition. Lower density is a desirable property in the wire and / or cable industry because it leads to a reduction in the overall cost of the composition.

[0017] In the embodiment of the present invention, the brominated flame retardant contains aromatically linked bromine and, in some embodiments, is considered to be a brominated styrene polymer. The brominated flame retardant has a weight-average molecular weight (Mw) of about 650 to about 75,000 and a bromine content of about 60% by weight or more. Preferably, the styrene polymer is polystyrene. In the embodiment of the present invention, a mixture of two or more brominated flame retardants can be used. A mixture of a brominated flame retardant and other non-halogenated flame retardants can also be used in the embodiment of the present invention.

[0018] In other embodiments, the brominated flame retardant is a brominated anionic styrene polymer, where the styrene polymer is typically formed via anionic polymerization using an alkyllithium initiator, and these brominated flame retardants generally have a weight-average molecular weight (Mw) of about 2,000 or more, preferably about 10,000 or more. In some embodiments, the brominated anionic styrene polymer has an Mw of about 8,000 to about 50,000, preferably about 10,000 to about 30,000, and more preferably about 10,000 to about 20,000.

[0019] Typically, brominated anionic styrene polymers contain about 60% by weight or more bromine, preferably about 66% by weight or more, and more preferably about 67% by weight or more. In some embodiments, brominated anionic styrene polymers contain about 60% to about 72% by weight bromine, more preferably about 66% to about 71% by weight bromine, and even more preferably about 67% to about 71% by weight bromine. Preferably, the brominated anionic styrene polymer is brominated anionic polystyrene. In some embodiments, the brominated anionic styrene polymer is brominated anionic polystyrene having a weight-average molecular weight of about 10,000 to about 20,000 and about 67% to about 69% by weight bromine. Information regarding the manufacture of brominated anionic styrene polymers is described, for example, in U.S. Patents 7,632,893 and 7,638,583.

[0020] In another embodiment, the brominated flame retardant is a low molecular weight brominated anionic styrene polymer having a weight-average molecular weight (Mw) of about 650 or more, preferably about 950 or more, and more preferably about 1000 or more. In some embodiments, these brominated anionic styrene polymers have an Mw in the range of about 650 to about 10,000, preferably about 750 to about 7,500, and more preferably about 1,000 to about 4,000.

[0021] Typically, low molecular weight brominated anionic styrene polymers contain about 60% by weight or more of bromine, preferably about 66% by weight or more, and more preferably about 70% by weight or more. In some embodiments, these brominated anionic styrene polymers contain about 60% to about 77% by weight of bromine, preferably about 66% to about 77% by weight of bromine, and more preferably about 70% to about 75% by weight of bromine.

[0022] Preferably, the low molecular weight brominated anionic styrene polymer is brominated anionic polystyrene. In some embodiments, the low molecular weight brominated anionic styrene polymer is brominated anionic polystyrene having a weight-average molecular weight of about 1000 to about 3000 and about 73% to about 77% by weight of bromine.

[0023] Low molecular weight brominated anionic styrene polymers can be formed by bromination reactions in organic solvents or in a "sea of ​​bromine" where bromine itself functions as both a brominater and a solvent. Information regarding the production of low molecular weight brominated anionic styrene polymers is described, for example, in International Patent Publications WO2017 / 176740 and WO2017 / 184350, and these polymers can be produced as described in U.S. Patents 7,632,893 and 7,638,583.

[0024] Another brominated flame retardant that can be used in the practice of the present invention may not be classified as a styrenic polymer because the number of repeating units of these molecules is relatively small. Similar to brominated styrenic polymers, these molecules also contain aromatic bond bromine and styrene repeating units. This brominated flame retardant is a brominated anionic chain transfer vinyl aromatic polymer containing about 70% by weight or more of bromine, preferably about 72% by weight or more of bromine, and a weight average molecular weight of about 1000 or more, preferably about 1250 or more. In some embodiments, the bromine content is in the range of about 70% to about 79% by weight, preferably about 72% to about 78% by weight, and Mw is in the range of about 1000 to about 21,000, preferably about 1250 to about 14,000, more preferably about 2000 to about 10,000.

[0025] Preferably, the brominated anionic chain transfer vinyl aromatic polymer is brominated anionic chain transfer polystyrene. In some embodiments, the brominated anionic chain transfer vinyl aromatic polymer is brominated anionic chain transfer polystyrene having a weight average molecular weight of about 2000 to about 10,000 and a bromine content of about 72% to about 78% by weight.

[0026] The brominated anionic chain transfer vinyl aromatic polymer can be formed by bromination in an organic solvent or in a sea of bromine (where bromine is both the brominating agent and the solvent). Information regarding the preparation of brominated anionic chain transfer vinyl aromatic polymers can be found, for example, in U.S. Pat. Nos. 8,420,876, 8,796,388, and 8,993,684.

[0027] Mixtures of two or more brominated flame retardants can be used in the practice of the present invention. In addition to brominated anionic styrenic polymers and / or brominated anionic chain transfer vinyl aromatic polymers, the flame retardant additive composition can contain one or more other brominated flame retardants. Suitable brominated flame retardants include hexabromocyclohexane, dibromoethyldibromocyclohex Sun, monochloropentabromocyclohexane, tetrabromocyclooctane, hexabromocyclododecane, bis(pentabromophenyl)ethane (decabromodiphenylethane), hexabromobenzene, dibromostyrene and its derivatives, pentabromodiphenyl oxide, octabromodiphenyl oxide (octabromodiphenyl ether), decabromodiphenyl oxide (decabromodiphenyl ether), 1,2-bis(tribromophenoxy)ethane, tetradecabromodiphenoxy Benzene, 2,4,6-tribromophenol allyl ether, dibromoneopentyl glycol, tribromoneopentyl alcohol, tetrabromobisphenol-A, tetrabromobisphenol-A diallyl ether, tetrabromobisphenol-A bis(2,3-dibromopropyl ether), bis(2,4,6-tribromophenoxyethyl)tetrabromobisphenol-A ether, tetrabromobisphenol-bis(2-hydroxyethyl) ether, tetrabromobisphenol-S, tetrabromobisphenol-S bis(2,3-dibromopropyl ether), brominated epoxy oligomers such as tribromophenol end-cap brominated epoxy oligomers, tetrabromobisphenol-A based brominated carbonate oligomers such as 2,4,6-tribromophenyl-terminated tetrabromobisphenol-A carbonate oligomers and phenoxy-terminated tetrabromobisphenol-A carbonate oligomers, brominated polystyrene, polystyrene and brominated polybutadi Ethyl phosphate block copolymer, poly(dibromophenylene oxide), poly(pentabromobenzyl acrylate), brominated phthalic acid, diallyl tetrabromophthalate, bis(2-ethylhexyl) tetrabromophthalate, tetrabromophthalimide, N,N-ethylene-bis(tetrabromophthalimide), tetrabromophthalic anhydride, mixed ester of tetrabromophthalic anhydride with diethylene glycol and propylene glycol, N,N'-ethylene-bis-(5,6-dibromonolbornane 2,Brominated phenoxy triazines such as 3-dicarboximide), tris(tribromophenyl)triazine, tris(tribromophenoxy)triazine, brominated maleimides such as tribromophenyl maleimide, brominated trimethylphenyl indane, brominated isocyanurates such as tris(2,3-dibromopropyl)isocyanurate, and tris(tribromoneopentyl) phosphate). Preferred brominated flame retardants for use in admixture with brominated anionic styrenic polymers and / or brominated anion chain transfer vinyl aromatic polymers include decabromodiphenyl ethane and N,N-ethylene-bis(tetrabromophthalimide).

[0028] Furthermore, in addition to the above-described brominated flame retardants, embodiments of the present invention include a polymer composition. The polymer composition is useful as a thermoplastic material or a thermosetting material. The polymer composition provides a coating for wires and / or cables together with the brominated flame retardant. Non-limiting examples of polymer compositions useful as thermoplastic plastics include polyurethanes, polyesters, polyamides, polyolefins, styrenic polymers, chlorinated polyethylene, and combinations thereof. Thermoplastic formulations for wires and / or cables are generally formed by crosslinking techniques including (a) moisture curing, (b) peroxide curing, or (c) electron beam curing techniques. Non-limiting examples of base polymer compositions suitable for crosslinking include polyolefins such as polyethylene, polyolefin copolymers such as poly(ethylene-vinyl acetate)(EVA) and poly(ethylene-ethyl acrylate)(EEA), and further polyolefin derivatives such as chlorinated polyethylene and silane-functionalized polyethylene.

[0029] Any components that may be present in a flame-retardant composition include inorganic compounds, antioxidants, impact modifiers, compatibilizers, halogenated polyethylenes, pigments, flame retardant synergists, anti-dripping agents, dyes, light stabilizers, UV stabilizers, fillers, defoamers, antibacterial agents, biocides, buffers, pH stabilizers, fixatives, antistatic agents, antifouling agents, wetting agents, softeners, water repellents, fluorescent whitening agents, plasticizers, emulsifiers, acid scavengers, radical scavengers, metal scavengers or deactivators, processing aids, release agents, lubricants, and Examples include anti-locking agents, antistatic agents, slip agents, foaming agents, anti-fogging agents, reinforcing agents, coupling agents, nucleating agents, other flame retardants, and other heat stabilizers.

[0030] Preferred optional components include inorganic compounds, antioxidants, impact modifiers, compatibilizers, halogenated polyethylenes, and pigments. In some preferred embodiments, one or more antioxidants, one or more compatibilizers, one or more impact modifiers, one or more halogenated polyethylenes, and / or one or more pigments are present in the additive composition. In some preferred embodiments, at least one inorganic compound and one or more other optional components selected from antioxidants, impact modifiers, compatibilizers, and halogenated polyethylenes are present in the flame retardant additive composition.

[0031] Inorganic compounds are preferred types of optional components. When used throughout this document, the term "inorganic component" refers to one or more inorganic compounds containing one or more metal atoms that do not have a hydrocarbyl group directly bonded to a metal atom(s). More preferably, at least one inorganic compound is present in the flame retardant additive composition.

[0032] Suitable inorganic compounds in practice of the present invention include talc, ammonium phosphate, ammonium phosphinate, antimony trioxide, antimony pentoxide, antimony phosphate, aluminum phosphinate, aluminum diethylphosphinate, sodium antimonate, calcium stearate, calcium borate, calcium phosphinate, magnesium hydroxide, magnesium aluminum carbonate hydroxide, zinc borate, zinc oxide, zinc stannate, zinc sulfide, zinc phosphate, zinc phosphinate, diethylzinc phosphate, zinc molybdate, and tin(I) oxide. Examples include titanium dioxide, titanium phosphate, α-zirconium phosphate, wollastonite, hydrotalcite, silane-modified aluminum silicate, glass fibers, and clays containing smectites such as montmorillonite, bentonite, nontronite, hectorite, laponite, beiderite, volconscoite, soconite, stevensite, and saponite; kaolin such as halloysite; mica such as reddikite; lectrite; thalassovit; keniite; permatite; vermiculite; attapulgate; and illite. If necessary, mixtures of two or more inorganic compounds may be used, and in some embodiments, more than one inorganic compound is preferred.

[0033] When present in a flame retardant composition, the inorganic compound is present in an amount of about 5% by weight or more, preferably about 10% by weight or more, or about 5% to about 40% by weight, preferably about 5% to about 30% by weight, and more preferably about 10% to about 25% by weight, based on the total weight of the additive composition. If more than one inorganic compound constitutes the inorganic component of the additive composition, these values ​​refer to the total amount of inorganic compounds present in the additive composition.

[0034] Antioxidants that can be used in practice of the present invention include phenolic antioxidants, thioesters, aromatic amines, phosphinates, and phosphorus antioxidants. Preferred antioxidants include 2,6-di-tert-butyl-4-methylphenol, tetrakis(3-(4-hydroxy-3,5-di-tert-butylphenyl)propionyloxymethyl)methane, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-s-triazine-2,4,6(1H,3H,5H)trione, octadecyl 3,5-di-tert-butyl-4-hydroxyhydrocinnamate, and 1,3,5-trimethicone. Lu-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene, 4,4'-methylenebis(2,6-di-tert-butyl-phenol), ethylenebis(oxyethylene)bis-(3-(5-tert-butyl-4-hydroxy-m-tolyl)-propionate), N,N'-(hexane-1,6-diyl)bis(3-(3,5-di-tert-butyl-4-hydroxyphenyl(propionamide), hexadeci) C-3,5-di-t-butyl-4-hydroxybenzoate, 2,2'-thiodiethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate],3-(3'5'-di-t-butyl-4'-hydroxyphenyl)propionic acid 13 ~C 15 Linear and branched alkyl esters, 3-(3',5'-di-t-butyl-4'-hydroxyphenyl)propionic acid C9-C 11Linear and branched alkyl esters, 2,2'-methylenebis(6-tert-butyl-4-methylphenol), 2,2'-ethylidenebis(4,6-di-tert-butylphenol), (1,1-di-tert-butyl)-4-hydroxyphenyl)methyl)ethylphosphonate, reaction products of N-phenylbenzeneamine and 2,4,4-trimethylpentene, dimyristyl thiodipropionate, distearyl disulfide, tetrakis(β-laurylthiopropionate)pentaerythritol 3,3'-Dioctadecyl thiodipropanoate, 3,3'-Didodecyl thiodipropanoate, Tris-(2,4-di-tert-butylphenyl) phosphate, Bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphate, (2,4,6-tri-tert-butylphenyl)(2-butyl-2-ethyl-1,3-propanediol) phosphate, Tetrakis(2,4-di-tert-butylphenyl)-4,4'-Biphenylene diphosphinate, Distearyl pentaerythritol diphosphate Litol, bis(2,4-dicumylphenyl)pentaerythritol diphosphate, tris(dipropylene glycol) phosphate, poly(dipropylene glycol)phenyl phosphate, diphenylisodecyl phosphate, phenyldiisodecyl phosphate, heptakis(dipropylene glycol) triphosphate, tris(nonylphenyl) phosphate, bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphate, fluorophosphinate 2,2'-ethylidenebis(4,6-di Examples include tris(2,4-di-tert-butylphenyl), 2,2'-methylenebis(4,6-di-tert-butylphenyl)octyl-phosphate, trilauryl trithiophosphite, 1,2-bis(3,5-di-tert-butyl-4-hydroxyhydrocinnamoyl)hydrazine, and a 1:1:2 combination of (3,5-di-tert-butyl-4-hydroxyphenyl)methylethoxyphosphinate calcium, polyethylene wax, and tris(2,4-di-tert-butylphenyl) phosphate. A mixture of two or more antioxidants can be used.Preferred antioxidants include tetrakis(3-(4-hydroxy-3,5-di-tert-butylphenyl)propionyloxymethyl)methane and tris-(2,4-di-tert-butylphenyl)phosphite; more preferably, a combination of tetrakis(3-(4-hydroxy-3,5-di-tert-butylphenyl)propionyloxymethyl)methane and tris-(2,4-di-tert-butylphenyl) phosphite.

[0035] Generally, impact modifiers are rubber or elastomers. Suitable impact modifiers in practice of the present invention include ethylene octene copolymer and ethylene hexene copolymer. Ethylene octene copolymer is a preferred impact modifier in practice of the present invention. Mixtures of impact modifiers may be used as needed.

[0036] The compatibilizer may be a thermoplastic elastomer, a maleic oxide copolymer of an olefin homopolymer or copolymer, or a polymer catalyst formed in situ. Suitable compatibilizers for use in the practice of the present invention include sodium ionomers of styrene-ethylene butadiene copolymers, particularly styrene-ethylene / butylene linear triblock copolymers, maleic anhydride-modified polypropylene homopolymers, and ethylene / methacrylic acid copolymers. Mixtures of compatibilizers can be used. A preferred compatibilizer is styrene-ethylene / butylene linear triblock copolymer.

[0037] Halogenated polyethylene is polyethylene containing halogen atoms. Examples of officially recognized halogenated polyethylene include polytetrafluoroethylene and polyethylene chloride. Mixtures of halogenated polyethylene can also be used.

[0038] Pigments are substances that color polymers and are generally used only when coloring is required for polymer brominated flame retardant compositions for wires and / or cables. Non-limiting examples of suitable pigments in the implementation of the present invention include mixed oxides of chromium, antimony, and titanium (Brown 24), mixed compounds of chromium, nickel, and titanium (Yellow 53), 1,8-bis(phenylthio)anthracene-9,10-dione (Solvent Yellow 163), titanium dioxide, carbon black, titanium dioxide, zinc sulfide, iron oxide, lead chromate and lead molybdate chromate, cadmium, and chromium oxide. Mixtures of two or more pigments can be used.

[0039] Flame-retardant polymer composition for use in wires and / or cables One embodiment of the present invention is a flame retardant composition for use in wires and / or cables, the composition comprising at least one polymer composition, at least one brominated flame retardant, and at least one synergistic agent, the content of which is about 0.0% by weight or more, wherein the brominated flame retardant contains aromatically linked bromine and is selected from a) a brominated styrene polymer having a weight-average molecular weight of about 650 to about 75,000 and a bromine content of about 60% by weight or more, and / or b) a brominated anionic chain-transfer vinyl aromatic polymer having a weight-average molecular weight of about 650 to about 75,000 and containing about 70% by weight or more bromine.

[0040] The optional components often included in flame-retardant polyolefin compositions are as described above.

[0041] A suitable polymer composition is one that is useful as a thermoplastic or thermosetting material. Non-limiting examples of polymer compositions useful as thermoplastics include polyurethanes, polyesters, polyamides, polyolefins, styrene polymers, polyethylene chloride, and combinations thereof. Thermoplastic formulations for wires and / or cables are generally formed by crosslinking techniques, including (a) moisture curing, (b) peroxide curing, or (c) electron beam curing. Non-limiting examples of base polymer compositions suitable for crosslinking include polyolefins such as polyethylene, polyolefin copolymers such as poly(ethylene-vinyl acetate) (EVA) and poly(ethylene-ethyl acrylate) (EEA), and polyolefin derivatives such as polyethylene chloride and silane-functionalized polyethylene.

[0042] In practice of the present invention, the brominated flame retardant contains aromatically linked bromine and, in some embodiments, is considered to be a brominated styrene polymer. The brominated flame retardant has a weight-average molecular weight (Mw) of about 650 to about 75,000 and a bromine content of about 60 wt% or more. Preferably, the styrene polymer is polystyrene. In practice of the present invention, a mixture of two or more brominated flame retardants can be used. A mixture of a brominated flame retardant and other non-halogenated flame retardants can also be used in practice of the present invention.

[0043] In other embodiments, the brominated flame retardant is a brominated anionic styrene polymer, where the styrene polymer is typically formed via anionic polymerization using an alkyllithium initiator, and these brominated flame retardants generally have a weight-average molecular weight (Mw) of about 2,000 or more, preferably about 10,000 or more. In some embodiments, the brominated anionic styrene polymer has an Mw of about 8,000 to about 50,000, preferably about 10,000 to about 30,000, and more preferably about 10,000 to about 20,000.

[0044] Typically, brominated anionic styrene polymers contain about 60% by weight or more bromine, preferably about 66% by weight or more, and more preferably about 67% by weight or more. In some embodiments, the brominated anionic styrene polymer contains about 60% to about 72% by weight of bromine. More preferably, it contains about 66% to about 71% by weight of bromine, and even more preferably, about 67% to about 71% by weight of bromine. Preferably, the brominated anionic styrene polymer is brominated anionic polystyrene. In some embodiments, the brominated anionic styrene polymer is brominated anionic polystyrene having a weight-average molecular weight of about 10,000 to about 20,000 and about 67% to about 69% by weight of bromine. Information regarding the manufacture of brominated anionic styrene polymers is described, for example, in U.S. Patents 7,632,893 and 7,638,583.

[0045] In another embodiment, the brominated flame retardant is a low molecular weight brominated anionic styrene polymer having a weight-average molecular weight (Mw) of about 650 or more, preferably about 950 or more, and more preferably about 1000 or more. In some embodiments, these brominated anionic styrene polymers have an Mw in the range of about 650 to about 10,000, preferably about 750 to about 7,500, and more preferably about 1,000 to about 4,000.

[0046] Typically, low molecular weight brominated anionic styrene polymers contain about 60% by weight or more of bromine, preferably about 66% by weight or more, and more preferably about 70% by weight or more. In some embodiments, these brominated anionic styrene polymers contain about 60% to about 77% by weight of bromine, preferably about 66% to about 77% by weight of bromine, and more preferably about 70% to about 75% by weight of bromine.

[0047] Preferably, the low molecular weight brominated anionic styrene polymer is brominated anionic polystyrene. In some embodiments, the low molecular weight brominated anionic styrene polymer is brominated anionic polystyrene having a weight-average molecular weight of about 1000 to about 3000 and about 73% to about 77% by weight of bromine.

[0048] Low molecular weight brominated anionic styrene polymers can be formed by bromination reactions in organic solvents or in a "sea of ​​bromine" where bromine itself functions as both a brominater and a solvent. Information regarding the production of low molecular weight brominated anionic styrene polymers is described, for example, in International Patent Publications WO2017 / 176740 and WO2017 / 184350, and these polymers can be produced as described in U.S. Patents 7,632,893 and 7,638,583.

[0049] Another brominated flame retardant that can be used in practice of the present invention may not be classified as a styrene polymer because it has a relatively small number of repeating units in these molecules. Similar to brominated styrene polymers, these molecules also contain aromatically linked bromine and styrene repeating units. This brominated flame retardant is a brominated anionic chain-transfer vinyl aromatic polymer containing about 70% by weight or more of bromine, preferably about 72% by weight or more of bromine, and a weight-average molecular weight of about 1000 or more, preferably about 1250 or more. In some embodiments, the bromine content is in the range of about 70% to about 79% by weight, preferably about 72% to about 78% by weight, and the Mw is in the range of about 1000 to about 21,000, preferably about 1250 to about 14,000, and more preferably about 2000 to about 10,000.

[0050] Preferably, the brominated anion chain transfer vinyl aromatic polymer is brominated anion chain transfer polystyrene. In some embodiments, the brominated anion chain transfer vinyl aromatic polymer is brominated anion chain transfer polystyrene having a weight-average molecular weight of about 2,000 to about 10,000 and about 72% to about 78% by weight of bromine.

[0051] Brominated anion chain transfer vinyl aromatic polymers can be formed by bromination in an organic solvent or in a sea of ​​bromine (where bromine is both the brominating agent and the solvent). Information regarding the preparation of nionic chain-transfer vinyl aromatic polymers can be found, for example, in U.S. Patents No. 8,420,876, No. 8,796,388, and No. 8,993,684.

[0052] In practice of the present invention, a mixture of two or more brominated flame retardants can be used. In addition to the brominated anionic styrene polymer and / or the brominated anion chain transfer vinyl aromatic polymer, the flame retardant additive composition may contain one or more other brominated flame retardants. Suitable brominated flame retardants include hexabromocyclohexane, dibromoethyldibromocyclohexane, monochloropentabromocyclohexane, tetrabromocyclooctane, hexabromocyclododecane, bis(pentabromophenyl)ethane (decabromodiphenylethane), hexabromobenzene, dibromostyrene and its derivatives, pentabromodiphenyl oxide, octabromodiphenyl oxide (octabromodiphenyl ether), decabromodiphenyl oxide (decabromodiphenyl ether), 1,2-bis(tribromophenoxy)ethane, tetradecabromodiphenoxybenzene, 2,4,6-tribromophenol allyl ether, dibromoneopentyl glycol, tribromoneopentyl alcohol, tetrabromobisphenol-A, tetrabromobisphenol A diallyl ether, tetrabromobisphenol-A bis(2,3-dibromopropyl ether), bis(2,4,6-tri Romophenoxyethyl) tetrabromobisphenol-A ether, tetrabromobisphenol-bis(2-hydroxyethyl) ether, tetrabromobisphenol-S, tetrabromobisphenol-S bis(2,3-dibromopropyl ether), brominated epoxy oligomers such as tribromophenol end-cap brominated epoxy oligomer, tetrabromobisphenol-A based brominated carbonate oligomers such as 2,4,6-tribromophenyl-terminated tetrabromobisphenol-A carbonate oligomer and phenoxy-terminated tetrabromobisphenol-A carbonate oligomer, brominated polystyrene, block copolymer of polystyrene and brominated polybutadiene, poly(dibromophenylene oxide), poly(pentabromobenzylate), brominated phthalate, diallyl tetrabromophthalate, bis(2-ethylhexyl) tetrabromophthalate, tetrabromophthalimide, N,Examples include N-ethylene-bis(tetrabromophthalimide), tetrabromophthalic anhydride, mixed esters of tetrabromophthalic anhydride with diethylene glycol and propylene glycol, N,N'-ethylene-bis-(5,6-dibromonorbornane 2,3-dicarboximide), tris(tribromophenyl)triazine, brominated phenoxytriazines such as tris(tribromophenoxy)triazine, brominated maleimides such as tribromophenylmaleimide, brominated trimethylphenylindan, brominated isocyanurates such as tris(2,3-dibromopropyl)isocyanurate, and tris(tribromoneopentyl)phosphate). Preferred brominated flame retardants for use in combination with brominated anionic styrene polymers and / or brominated anion chain-transfer vinyl aromatic polymers include decabromodiphenylethane and N,N-ethylene-bis(tetrabromophthalimide).

[0053] One embodiment of the present invention is a flame retardant composition for use in wires and / or cables, the composition comprising at least one polymer composition, at least one brominated flame retardant, the brominated flame retardant being selected from a) a brominated styrene polymer having a weight-average molecular weight of about 650 to about 75,000 and a brominated content of about 60% by weight or more, and / or b) a brominated anionic chain-transfer vinyl aromatic polymer containing about 70% by weight or more brominate, and combining at least one synergistic agent, and comprising a first step of extruding the mixture of the first step and coating wires and / or cables with it.

[0054] Further embodiments of the process for forming a flame-retardant composition include at least one poly The first step comprises combining a Mer composition, at least one synergist, and at least one brominated flame retardant, the brominated flame retardant comprising aromatically linked bromine and selected from a) a brominated styrene polymer having a weight-average molecular weight of about 650 to about 75,000 and a bromine content of about 60% by weight or more, and / or b) a brominated anionic chain-transfer vinyl aromatic polymer having a bromine content of about 70% by weight or more, and at least one silanol catalyst. The second step is to extrude the mixture from the first step to coat wires and / or cables. The third step is to expose the mixture from the first step to either increased temperature, external moisture, or both, so that the product reaches a desired degree of crosslinking.

[0055] A further embodiment of a process for forming a flame-retardant composition, the process comprising a first step comprising a combination of at least one polymer composition, at least one synergist, and at least one brominated flame retardant, the brominated flame retardant comprising aromatically linked bromine, selected from a) a brominated styrene polymer having a weight-average molecular weight of about 650 to about 75,000 and a bromine content of about 60% by weight or more, and / or b) having a bromine content of about 70% by weight or more. A second step of extruding the mixture from the first step to coat wires and / or cables. A third step of irradiating the mixture of coated wires and / or cables with an electron beam at an effective electron beam irradiation dose.

[0056] Brominated flame retardants and polymer compositions include those described above. When preparing the compositions of the present invention, the individual components can be blended separately and / or in subcombinations with a substrate or host polymer in appropriate proportions.

[0057] When a flame-retardant polyolefin composition is formed from a flame-retardant additive composition, the flame-retardant additive composition is usually about 40% by weight or more of the flame-retardant polyolefin composition, or about 40% to about 80% by weight of the flame-retardant polyolefin composition, based on the total weight of the flame-retardant polyolefin composition.

[0058] Various methods can be used to prepare the compositions of the present invention. The brominated flame retardant and other components can be compounded using compounding equipment such as a single-screw extruder, a twin-screw extruder, or a Buss kneader. Preferably, compounding is carried out using an extruder, more preferably a twin-screw extruder. Other components used in the practice of the present invention can be added to the first feed port of the extruder or further downstream of the extruder. In the extruder, many components usually melt when mixed together. The extruded material from the extruder is usually converted into granules or pellets by cooling the strands of the extruded polymer and refining the solidified strands, or by subjecting the extruded material to simultaneous die-face pelletization and water or air cooling. If necessary, the compositions of the present invention can be formulated as a powder blend or granule blend of the components of the composition.

[0059] In certain embodiments, a masterbatch can be formed comprising a polymer composition and at least one brominated flame retardant. The masterbatch is typically a mixture having a high concentration of brominated flame retardant relative to a thermoplastic resin. Typically, the masterbatch is later blended with more polymer compositions to form a final product in which the brominated flame retardant, other components, and polymer compositions are in desired proportions. The masterbatch can be used in thermoplastic formulations.

[0060] Formation of coatings on wires and / or cables In particular, these compositions of the present invention are useful as coatings for wires and / or cables. Flame retardants are used in the formulation of wires and / or cables to meet the fire resistance requirements of specific applications, such as household appliances, building and construction, automotive cables, and solar power generation wires. In these applications, flame retardancy is imparted by incorporating various flame retardant chemicals and technologies (Br, P, metal hydroxides) into the insulating coating of the conductor. Such flame retardant chemicals are also used in the formulation of the jacket (the layer on top of the insulating layer). The insulating layer or jacket may be (1) thermoplastic or (2) thermosetting (crosslinked). Thermoplastic and thermosetting formulations may have polyolefins (PP, PE) as the base polymer. In addition to polyolefins, the base polymer may also be polyurethane or chlorinated polyethylene. Polyolefins can be crosslinked by (a) moisture curing, (b) peroxide curing, or (c) electron beam curing techniques.

[0061] Typically, the composition is prepared in a compounding extruder, which mixes and uniformly disperses all the components. The extruded compound is then formed into pellets. Typically, the pellets are then fed into a wireline extruder to coat wires. In the case of thermosetting wires, the coated wires are crosslinked in a second step based on the chemical process of a curing reaction.

[0062] A suitable curing chemical structure for the present invention is curing by moisture. In the case of moisture curing, the coated wire is placed in a sauna bath with high temperature and humidity.

[0063] For hygroscopic curing, any process known in the art is suitable for this purpose. Typically, the above compositions further include a silanol catalyst to promote hygroscopic curing. Silanol catalysts known in the art for crosslinking alkoxysilane polymers can be used in the compositions of the present invention. Such catalysts include organic bases, carboxylic acids, organotitanate esters, lead, cobalt, iron, nickel, zinc, tin complexes or carboxylates, such as dibutyltin dilaurate, dioctyltin maleate, dibutyltin diacetic acid, dibutyltin dioctylate, tin acetate, tin octanoate, lead naphthenate, zinc caprylate, and cobalt naphthenate. Tin carboxylates, particularly dibutyltin dilaurate and dioctyltin maleate, are silanol catalysts that are especially useful in the compositions of the present invention. The compositions may be exposed to either high temperatures and / or external moisture, and in the case of high temperatures, they may be exposed for a period sufficient to achieve the desired degree of crosslinking, usually in the range from ambient temperature to below the melting point of the polymer. The curing temperature after molding should be above 0°C. [Examples]

[0064] general component The components used to manufacture the flame-retardant composition are provided in the examples. In the table, some of the components used are referred to by their trade names.

[0065] Analysis method When analyzing the properties of brominated flame retardants and their polyolefin compositions used in the implementation of the present invention, known analytical methods can be used or adapted. Where applicable, the brominated flame retardants and / or the resulting flame-retardant polyolefin compositions were measured using the following methods.

[0066] The analytical methods used or adapted for analyzing polymer BFRs are described in WO2022 / 031932A1, which is incorporated herein by reference.

[0067] UL-VW-1 Combustion Test. The VW-1 combustion test is performed on three or six samples of a specific insulated conductor according to the provisions of UL2556. This requires five 15-second applications to a 610 mm (24 inch) long vertical test specimen, with a 125 mm flame applied at a 20° angle. A 12.5 ± 1 mm (0.5 ± 0.1 inch) strip of kraft paper is attached to the test specimen 254 ± 2 mm (10 ± 0.1 inch) above the point of flame impact. A continuous horizontal cotton layer is placed on the floor of the test chamber, centered on the vertical axis of the test specimen, with the top surface of the cotton 235 ± 6 mm (9.25 ± 0.25 inch) from the point where the blue inner conical tip of the flame impacts the test specimen. (Located below) Failure of the test is determined based on whether 25% of the kraft paper tape flag burns, whether the cotton stuffing ignites, or whether the test piece burns for more than 60 seconds with any of five flame applications. As an additional measure of combustion performance, the length of the non-carbonized insulator at the end of the test ("non-carbonized length to the flag") is measured. If the cotton ignites in VW-1, it indicates whether the falling material ignited the layer of cotton.

[0068] Each sample was prepared by feeding each component separately in powder form into a twin-screw extruder (ZSK30 (30mm), Werner & Pfleiderer Coperion GmbH), and then mixing and dissolving all the components together to form the final product.

[0069] In all the tables below, the amounts of each component and the amount of bromine are reported as weight percent.

[0070] Example 1 Examples of coated wires and / or cables include those manufactured by moisture curing. Moisture curing processes are well known to those skilled in the art. First, a flame retardant masterbatch (FR MB) (Table 6) was prepared in a 30 mm twin-screw extruder, and then the strands were pelletized. The pellets were then dried in a desiccator oven at 60-70°C to reduce the moisture level to less than 100 ppm. The dried material was then used to manufacture coated wires (Table 1). Comparatives 1 and 2 are commercially available non-polymer brominated flame retardant masterbatches (MB) of SAYTEX®-8010. Example 1 is a polymer brominated flame retardant masterbatch (MB) manufactured based on the disclosures contained herein. [Table 1]

[0071] The above FR MB was mixed with silane copolymer (Aquathene AQ120000) and silanol catalyst (Aquathene CM04482) (Table 1) in a 3-zone barrel, L / D (length to diameter ratio) 25:1, 3 / 4-inch BRABENDER® single-screw extruder fitted with a Maddock mixing head. A 20 / 40 / 20 mesh screen pack was used during extrusion. The temperature profile used in the extruder was 155°C / 175°C / 185°C, with the die head temperature set to 185°C. The extruder operated at 65 rpm, and the line speed was 5 meters per minute. The resulting 14AWG copper wire with an insulation thickness of 0.030 inches was immediately cooled in a water bath and then wire-sealed. The wire was wound into a pool. The wire spool was then immersed in 90°C water for 12 hours to complete the moisture curing process. The cured wire was then subjected to a flame resistance (VW-1) test. [Table 2] [Table 3]

[0072] The VW-1 data (Table 2) demonstrates that the flame retardant of the present invention can provide the VW-1 flame retardant performance even without the added synergistic agent (ZnO). However, similar formulations using non-polymeric S-8010 do not provide these specific properties.

[0073] Any component referred to by a chemical name or chemical formula in this specification or in the claims, whether referred to in the singular or plural, is identified as existing before contact with another substance referred to by a chemical name or chemical type (e.g., another component, solvent, etc.). It is irrelevant what kind of chemical changes, transformations, and / or reactions may occur in the resulting mixture or solution, for such changes, transformations, and / or reactions are natural consequences of bringing together specific components under the conditions required in accordance with this disclosure. Thus, this component is identified as the component brought together in connection with the performance of a desired operation or the formation of a desired composition. Furthermore, even when the claims of this specification refer to a substance, component, or component in the present tense (e.g., "includes," "is"), this substance, component, or component is referred to as if it existed immediately before it first came into contact with, blended with, or mixed with one or more other substances, components, and / or components in accordance with this disclosure. Thus, a substance, component, or component is referred to in accordance with this disclosure and the chemists' claims. If carried out in accordance with normal skill, there is no substantial concern regarding the fact that the original identity may have been lost due to chemical reactions or transformations during the process of contact, blending, or mixing.

[0074] The present invention may include, consist of, or essentially consist of the materials and / or procedures listed herein.

[0075] As used herein, the term “about” modifying the amount of a component in the composition of the present invention or used in the method of the present invention refers to the variation in numerical amounts that may occur, for example, due to typical measurement and liquid handling procedures used in the real world to produce concentrates or working solutions, careless errors in these procedures, differences in the manufacture, source, or purity of the components used in the production of the composition or the implementation of the method. The term “about” also encompasses different amounts resulting from different equilibrium conditions of compositions obtained from a particular initial mixture. Whether modified by the term “about” or not, the claims include equivalent amounts.

[0076] Unless expressly indicated otherwise, the articles “a” or “an,” as used herein, are not intended, nor should they be construed as limiting, the description or claims to a single element to which the article refers. Rather, as used herein, the articles “a” or “an,” unless otherwise specified in the text, are intended to encompass one or more such elements.

[0077] The present invention is susceptible to considerable variability in its implementation. Therefore, the foregoing description is not intended to limit the invention to the specific examples presented above, nor should it be construed as such.

Claims

1. A flame-retardant composition for use in wires and / or cables, At least one polymer composition, At least one brominated flame retardant, and It contains at least one synergistic agent in an amount of 0.0% by weight or more, The brominated flame retardant contains aromatically linked bromine, and a) Brominated styrene polymer having an average molecular weight of approximately 650 to approximately 75,000 and a bromine content of approximately 60% by weight or more. and / or b) the flame retardant composition selected from a brominated anionic chain transfer vinyl aromatic polymer having an average molecular weight of about 650 to about 75,000 and containing about 70% by weight or more of bromine.

2. The flame retardant composition according to claim 1, wherein the brominated flame retardant has a weight-average molecular weight (Mw) of about 2,000 to about 50,000, preferably about 8,000 to about 50,000, more preferably about 10,000 to about 30,000, and most preferably about 10,000 to about 20,000.

3. The flame retardant composition according to claim 1, wherein the brominated flame retardant is a brominated anion-transfer vinyl aromatic polymer containing about 70% by weight or more of bromine, preferably about 72% by weight or more of bromine and about 1000 or more, preferably about 1250 or more, weight-average molecular weight.

4. The flame retardant composition according to claim 1, wherein the brominated flame retardant has a bromine content of about 67% by weight or more, more preferably about 68% by weight or more.

5. The flame-retardant composition according to claim 1, wherein the polymer composition comprises polyurethane, polyester, polyamide, polyolefin, styrene polymer, chlorinated polyethylene, and / or a combination thereof.

6. The flame retardant composition according to claim 1, wherein the polymer composition comprises polyolefins, for example, polyethylene and polyolefin copolymers, for example, poly(ethylene-vinyl acetate) (EVA) and poly(ethylene-ethyl acrylate) (EEA), and polyolefin derivatives such as chlorinated polyethylene and silane-functionalized polyethylene.

7. The flame retardant composition according to claims 1 to 6, further comprising a silanol catalyst.

8. Furthermore, the flame-retardant composition according to claim 7 is substantially zinc-free.

9. The flame retardant composition according to any one of claims 1 to 8, wherein the synergistic agent comprises antimony oxide.

10. A coated wire and / or cable, wherein the coating material comprises the flame-retardant composition described in any of the prior claims.

11. A process for forming a flame-retardant composition for use in wires and / or cables, wherein the process comprises: i. At least one polymer composition and ii. At least one brominated flame retardant, comprising aromatically linked bromine, and selected from a) a brominated styrene polymer having an average molecular weight of about 650 to about 75,000 and a bromine content of about 60% by weight or more, and / or b) a brominated anion-transfer vinyl aromatic polymer having a bromine content of about 70% by weight or more; and iii. One step consisting of a combination of at least one synergistic agent, The process comprising a second step of extruding the mixture from the first step to coat a wire and / or cable.

12. A process for forming the flame retardant composition according to claim 11, wherein the brominated flame retardant has a weight-average molecular weight (Mw) of about 2,000 to about 50,000, preferably about 8,000 to about 50,000, more preferably about 10,000 to about 30,000, and most preferably about 10,000 to about 20,000.

13. A process for forming the flame retardant composition according to claim 11, wherein the brominated flame retardant is a brominated anion-transfer vinyl aromatic polymer containing about 70% by weight or more of bromine, preferably about 72% by weight or more of bromine, and about 1000 or more, preferably about 1250 or more, weight-average molecular weight.

14. A process for forming the flame retardant composition according to claim 11, wherein the brominated flame retardant has a bromine content of about 67% by weight or more, more preferably about 68% by weight or more.

15. A process for forming the flame retardant composition according to any one of claims 11 to 14, wherein the synergistic agent comprises antimony oxide.

16. A process for forming a flame-retardant composition, wherein the process comprises: (a) i. At least one polymer composition and ii. At least one synergistic agent, iii. At least one brominated flame retardant containing aromatically linked bromine, selected from a) a brominated styrene polymer having a molecular weight of about 650 to about 75,000 and a bromine content of about 60% by weight or more, and / or b) a brominated anion-transfer vinyl aromatic polymer containing about 70% by weight or more bromine, iv. A first step comprising a combination of at least one silanol catalyst, (b) A second step of extruding the mixture from the first step to cover the wire and / or cable, (c) The process comprising a third step of exposing the mixture from the first step to either an increased temperature, external moisture, or both, so that the product reaches a desired degree of crosslinking.

17. A process for forming the flame retardant composition according to claim 16, wherein the brominated flame retardant has a weight-average molecular weight (Mw) of about 2,000 to about 50,000, preferably about 8,000 to about 50,000, more preferably about 10,000 to about 30,000, and most preferably about 10,000 to about 20,000.

18. A process for forming the flame retardant composition according to claim 16, wherein the brominated flame retardant is a brominated anion-transfer vinyl aromatic polymer containing about 70% by weight or more bromine, preferably about 72% by weight or more bromine and a weight-average molecular weight of about 1000 or more, preferably about 1250 or more.

19. A process for forming the flame retardant composition according to claim 16, wherein the brominated flame retardant has a bromine content of about 67% by weight or more, more preferably about 68% by weight or more.

20. A process for forming the flame retardant composition according to any one of claims 16 to 19, wherein the mixture of the first step is substantially zinc-free.

21. A process for forming the flame retardant composition according to any one of claims 19 to 20, wherein the synergistic agent comprises antimony oxide.

22. A coated wire and / or cable comprising a coating material containing a flame-retardant composition manufactured by the process described in any one of claims 11 to 21.

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