Polymer brominated flame retardant compositions for wires and / or cables

Abstract

The present invention relates to flame-retardant compositions for wires and / or cables, as well as polymeric brominated flame-retardant compositions. Brominated flame retardants contain aromatically bonded bromine and, in some embodiments, are determined to be brominated styrene polymers. Brominated flame retardants have a weight-average molecular weight (Mw) of about 650 to about 75,000 and a bromine content of about 60 wt% or more. The present invention further relates to processes for forming flame-retardant compositions using different curing methods, including but not limited to electron beam and peroxide curing.

Description

Technical Field

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

Background Art

[0002] In many cases, wires and cables in electric conduit pipes, household appliances, or automobiles have only one polymer layer. This layer needs to perform several functions simultaneously, while in other low - voltage cables, medium - voltage cables, and high - voltage cables, these functions are exerted by separate layers. Therefore, the polymer compositions used in the manufacture of electric conduit pipes, household appliances, or wires for automobiles must simultaneously meet several difficult requirements, including good insulation behavior, good mechanical properties, especially good abrasion resistance, good flame - retardant properties, good heat - distortion resistance, the ability to withstand low temperatures, resistance to water and chemicals, and good processing properties.

[0003] Many plastics containing polyolefins are flame - retarded to minimize the spread of fire. In WO2005 / 095685 and WO2022 / 031932, polybrominated anionic styrene - based polymers are used in combination with at least one synergist to flame - retard polyolefins. WO2001 / 029124 discloses polyolefins added with a flame - retardant containing tetrabromobisphenol - A bis(2,3 - dibromopropyl ether) and tetrabromobisphenol - S bis(2,3 - dibromopropyl ether). 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 anionic chain - transfer vinyl aromatic polymers capable of flame - retarding polyolefins.

[0004] Flame retardants are used in wire and / or cable formulations to obtain the flame retardant properties required for specific applications such as home appliances, building and construction, automotive cables, and solar power wires. In these applications, the insulating coating covering the conductor is made flame-retardant by incorporating various flame retardant chemistry or techniques (such as bromine, phosphorus, and metal hydroxides (e.g., magnesium hydroxide, aluminum hydroxide)). Such flame retardant chemistry is also used in sheath (the layer on top of the insulation) formulations. The insulation or sheath may be (1) thermoplastic or (2) thermosetting (crosslinked).

[0005] Non-limiting examples of thermoplastics for insulating or covering purposes include polyurethane, polyester, polyamide, polyolefin, styrene polymers, chlorinated polyethylene, and combinations thereof.

[0006] Thermosetting 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 polymers suitable for crosslinking include polyolefins such as polyethylene, and polyolefin copolymers such as poly(ethylene-vinyl acetate) (EVA) and poly(ethylene ethyl acrylate) (EEA), as well as derivatives of polyolefins such as chlorinated polyethylene or silane-functionalized polyethylene.

[0007] Existing non-polymeric brominated flame retardants (BFRs) often have melting temperatures higher than the process conditions and need to be ground to very small, uniform particle sizes (average less than approximately 10 microns) before they can be used in wire and / or cable formulations. This negatively impacts the smoothness of the wire insulation surface. In addition to the costly and / or time-consuming grinding process, non-polymeric BFRs often generate high extrusion back pressure during compounding.

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

[0009] The present invention provides flame-retardant compositions comprising thermoplastics for wires and / or cables. Non-limiting examples of thermoplastics include polyurethanes, polyesters, polyamides, polyolefins, styrene polymers, chlorinated polyethylene, and combinations thereof. The flame retardant is a brominated polymer flame retardant. Polymeric brominated flame retardants (PBFRs) are based on a polystyrene backbone and are synthesized by an aromatic bromination process. Such PBFR formulations are suitable for a variety of wire and / or cable applications, offering unique properties previously impossible with existing brominated flame retardant technologies.

[0010] Another aspect of the present invention provides flame retardant compositions comprising thermosetting formulations for wires and / or cables. Thermosetting 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 polymers suitable for crosslinking include polyolefins such as polyethylene, and polyolefin copolymers such as poly(ethylene-vinyl acetate) (EVA) and poly(ethylene ethyl acrylate) (EEA), as well as derivatives of polyolefins such as chlorinated polyethylene or silane-functionalized polyethylene. The flame retardant is a brominated polymer flame retardant. Polymeric brominated flame retardants (PBFRs) are based on a polystyrene backbone and are synthesized by an aromatic bromination process. Such PBFR formulations are suitable for a variety of wire and / or cable applications, offering unique properties that were previously impossible with existing brominated flame retardant technologies.

[0011] Other embodiments of the present invention include processes for preparing the flame-retardant compositions and flame-retardant thermoplastics or flame-retardant thermosetting compositions of the present invention, and the use thereof 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 advantages of this brominated polymer flame retardant are numerous. For example, existing non-polymer BFRs have a melting temperature higher than the process conditions. Therefore, non-polymer BFRs need to be ground to a very small and uniform particle size (average less than about 10 microns) before they can be used in wire and / or cable formulations. However, the polymer flame retardant of the present invention has a glass transition temperature (Tg) lower than the typical process temperature of wire and / or cable (Tg less than about 145°C for a process temperature of about 200°C). Therefore, at the process temperature, the polymer BFR readily melts and blends with the other components of the formulation.

[0014] Furthermore, unlike existing polymeric BFRs and non-polymeric BFRs, the novel polymeric BFR formulations of the present invention have a high melt index, resulting in lower extrusion back pressure during the compounding process and wire extrusion process (a higher melt index means better polymer flow at a given pressure and temperature). Therefore, the present invention enables compounders and cable manufacturers to extrude at higher rates (lb / h or m / h).

[0015] Unlike previously disclosed polymeric BFRs, the polymeric brominated flame retardants of the present invention offer higher thermal stability. Polymeric BFRs claimed in this application in other inventions to be used in wire and / or cable applications are often aliphatic brominated polymers, in contrast to the polymeric BFRs of the present invention in which bromine is bonded to an aromatic ring. Aromatic bromines have higher thermal stability than aliphatic bromines. Higher thermal stability means that (a) the formulation can be used at higher processing temperatures, (b) the run time when used in wire coating can be extended, and (c) recyclability can be improved.

[0016] In the embodiment of the present invention, the brominated flame retardant contains aromatically bonded bromine and, in some embodiments, is determined 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 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.

[0017] In other embodiments, the brominated flame retardant is a brominated anionic styrene polymer, which is typically formed via anionic polymerization using an alkyllithium initiator. 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.

[0018] Typically, brominated anionic styrene polymers contain about 60 wt% or more bromine, preferably about 66 wt% or more, and more preferably about 67 wt% or more. In some embodiments, the brominated anionic styrene polymer contains about 60 wt% to about 72 wt% bromine, more preferably about 66 wt% to about 71 wt% bromine, and even more preferably about 67 wt% to about 71 wt% 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 wt% to about 69 wt% bromine. Information regarding the preparation of brominated anionic styrene polymers is found, for example, in U.S. Patents 7,632,893 and 7,638,583.

[0019] 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 7500, and more preferably about 1000 to about 4000.

[0020] Typically, low molecular weight brominated anionic styrene polymers contain about 60 wt% or more bromine, preferably about 66 wt% or more, and more preferably about 70 wt% or more. In some embodiments, these brominated anionic styrene polymers contain about 60 wt% to about 77 wt% bromine, more preferably about 66 wt% to about 77 wt% bromine, and even more preferably about 70 wt% to about 75 wt% bromine.

[0021] 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 wt% to about 77 wt% bromine.

[0022] Low molecular weight brominated anionic styrene polymers can be formed by bromination in an organic solvent or in a large amount of bromine (bromine is both the brominater and the solvent). Information regarding the preparation of low molecular weight brominated anionic styrene polymers can be found, for example, in International Patent Publications WO2017 / 176740 and WO2017 / 184350. These polymers can also be prepared as described in U.S. Patents 7,632,893 and 7,638,583.

[0023] 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 bonded bromine and styrene repeating units. This brominated flame retardant is a brominated anionic chain-transfer vinyl aromatic polymer containing about 70 wt% or more of bromine, preferably about 72 wt% or more, 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 wt% to about 79 wt%, preferably about 72 wt% to about 78 wt%, and 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.

[0024] 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 2,000 to about 10,000 and about 72 wt% to about 78 wt% bromine.

[0025] Brominated anionic chain-transfer vinyl aromatic polymers can be formed by bromination in an organic solvent or in a large amount of bromine (bromine is both a brominater and a solvent). Information regarding the preparation of brominated anionic chain-transfer vinyl aromatic polymers can be found, for example, in U.S. Patents 8,420,876, 8,796,388, and 8,993,684.

[0026] In the implementation of the present invention, a mixture of two or more brominated flame retardants can be used. In addition to brominated anionic styrene 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, 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-tribromophenyl 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-capped brominated epoxy oligomers, 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, polystyrene and brominated polybut Tadiene 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 Examples include bis-(5,6-dibromonolbornane 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 anionic chain-transfer vinyl aromatic polymers include decabromodiphenylethane and N,N-ethylene-bis(tetrabromophthalimide).

[0027] In addition to the brominated flame retardant described above, embodiments of the present invention include a polymer composition. This polymer composition is useful as a thermoplastic material or a thermosetting material. This polymer composition provides a coating for wires and / or cables together with the brominated flame retardant. Non-limiting examples of polymer compositions useful as thermoplastics include polyurethanes, polyesters, polyamides, polyolefins, styrenic polymers, chlorinated polyethylene, and combinations thereof. Thermosetting 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, and polyolefin copolymers such as poly(ethylene-vinyl acetate) (EVA) and poly(ethylene ethyl acrylate) (EEA), and further derivatives of polyolefins such as chlorinated polyethylene or silane-functionalized polyethylene.

[0028] Optional components that may be included in the flame-retardant composition include inorganic compounds, antioxidants, impact modifiers, compatibilizers, halogenated polyethylene, pigments, flame-retardant synergists, drip inhibitors, dyes, light stabilizers, ultraviolet stabilizers, extenders, defoamers, antibacterial agents, biocides, buffers, pH stabilizers, fixatives, antistatic agents, antifouling agents, water repellents, fluorescent brighteners, plasticizers, emulsifiers, acid scavengers, radical scavengers, metal scavengers or deactivators, processing aids, mold release agents, lubricants, antiblocking agents, antistatic agents, slip agents, foaming agents, antifogging agents, reinforcing agents, coupling agents, nucleating agents, other flame retardants, and other heat stabilizers.

[0029] 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.

[0030] Inorganic compounds are preferred types of optional components. As 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.

[0031] Suitable inorganic compounds in the practice of this invention (some of which function as synergistic agents) include: Examples include clay, 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, tin(IV) oxide, 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; rectolite; thalassovit; kenyite; permatite; vermiculite; attapulgate; and illite. If necessary, a mixture of two or more inorganic compounds can be used, and in some embodiments, one or more inorganic compounds are preferred.

[0032] When present in a flame-retardant composition, the inorganic compound(s) constitute about 10 wt% or more, preferably about 15 wt% or more, more preferably about 25 wt% or more, based on the total weight of the additive composition, or about 10 wt% to about 70 wt%, preferably about 15 wt% to about 60 wt%, more preferably about 15 wt% to about 60 wt%. 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.

[0033] 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, 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene, and 4,4'-methylenebis(2,6- C of di-tert-butylphenol), 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), hexadecyl-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 product 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, Diphosphate Bis(2,4-dicumylphenyl)pentaerythritol acid, 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, 2,2'-ethylidenebis(4,6-di-tert) fluorophosphinate 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.

[0034] 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.

[0035] 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.

[0036] Halogenated polyethylene is polyethylene containing halogen atoms. Suitable halogenated polyethylenes include polytetrafluoroethylene and chlorinated polyethylene. Mixtures of halogenated polyethylenes can be used.

[0037] Pigments are substances used to color polymers and are generally used only when color is desired in polymeric brominated flame retardant compositions for wires and / or cables. Non-limiting examples of pigments suitable for the practice 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, and 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.

[0038] Flame-retardant polymer compositions for wires and / or cables One embodiment of the present invention is a flame retardant composition for wires and / or cables comprising at least one polymer composition, at least one brominated flame retardant, and at least one synergistic agent in an amount greater than about 0.0 wt%, wherein the brominated flame retardant contains aromatically bonded bromine and is 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 wt% or more, and / or b) about 650 to about 75,000 The flame retardant composition is selected from brominated anionic chain-transfer vinyl aromatic polymers having a weight-average molecular weight and containing approximately 70 wt% or more bromine.

[0039] The optional components often included in flame-retardant polyolefin compositions are as described above.

[0040] Suitable polymer compositions are those useful as thermoplastic or thermosetting materials. Non-limiting examples of polymer compositions useful as thermoplastics include polyurethanes, polyesters, polyamides, polyolefins, styrene polymers, chlorinated polyethylene, and combinations thereof. Thermosetting 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, and polyolefin copolymers such as poly(ethylene-vinyl acetate) (EVA) and poly(ethylene ethyl acrylate) (EEA), as well as derivatives of polyolefins such as chlorinated polyethylene or silane-functionalized polyethylene.

[0041] In the embodiment of the present invention, the brominated flame retardant contains aromatically bonded bromine and, in some embodiments, is determined 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 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.

[0042] In other embodiments, the brominated flame retardant is a brominated anionic styrene polymer, which is typically formed via anionic polymerization using an alkyllithium initiator. 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.

[0043] Typically, brominated anionic styrene polymers contain about 60 wt% or more bromine, preferably about 66 wt% or more, and more preferably about 67 wt% or more. In some embodiments, the brominated anionic styrene polymer contains about 60 wt% to about 72 wt% bromine, more preferably about 66 wt% to about 71 wt% bromine, and even more preferably about 67 wt% to about 71 wt% 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 wt% to about 69 wt% bromine. Information regarding the preparation of brominated anionic styrene polymers is found, for example, in U.S. Patents 7,632,893 and 7,638,583.

[0044] 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 7500, and more preferably about 1000 to about 4000.

[0045] Typically, low molecular weight brominated anionic styrene polymers contain approximately 60 wt% or more bromine, The polymer contains approximately 66 wt% or more bromine, more preferably about 70 wt% or more. In some embodiments, these brominated anionic styrene polymers contain approximately 60 wt% to approximately 77 wt% bromine, more preferably about 66 wt% to approximately 77 wt% bromine, and even more preferably about 70 wt% to approximately 75 wt% bromine.

[0046] 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 wt% to about 77 wt% bromine.

[0047] Low molecular weight brominated anionic styrene polymers can be formed by bromination in an organic solvent or in a large amount of bromine (bromine is both the brominater and the solvent). Information regarding the preparation of low molecular weight brominated anionic styrene polymers can be found, for example, in International Patent Publications WO2017 / 176740 and WO2017 / 184350. These polymers can also be prepared as described in U.S. Patents 7,632,893 and 7,638,583.

[0048] 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 bonded bromine and styrene repeating units. This brominated flame retardant is a brominated anionic chain-transfer vinyl aromatic polymer containing about 70 wt% or more of bromine, preferably about 72 wt% or more, 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 wt% to about 79 wt%, preferably about 72 wt% to about 78 wt%, and 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.

[0049] 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 2,000 to about 10,000 and about 72 wt% to about 78 wt% bromine.

[0050] Brominated anionic chain-transfer vinyl aromatic polymers can be formed by bromination in an organic solvent or in a large amount of bromine (bromine is both a brominater and a solvent). Information regarding the preparation of brominated anionic chain-transfer vinyl aromatic polymers can be found, for example, in U.S. Patents 8,420,876, 8,796,388, and 8,993,684.

[0051] In carrying out 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, and tetrabromobisphenol. Brominated epoxy oligomers such as tribromobisphenol-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), tribromophenol end-cap brominated epoxy oligomers, brominated carbonate oligomers based on tetrabromobisphenol-A such as 2,4,6-tribromophenyl-terminated tetrabromobisphenol-A carbonate oligomers and phenoxy-terminated tetrabromobisphenol-A carbonate oligomers, brominated polystyrene, block copolymers of polystyrene and brominated polybutadiene, poly(dibromophenylene) Examples include oxides, poly(pentabromobenzyl acrylate), brominated phthalates, diallyl tetrabromophthalate, bis(2-ethylhexyl) tetrabromophthalate, tetrabromophthalimide, N,N-ethylene-bis(tetrabromophthalimide), tetrabromophthalic anhydride, mixed esters of tetrabromophthalic anhydride with diethylene glycol and propylene glycol, N,N'-ethylene-bis-(5,6-dibromonolbornane 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 anionic chain-transfer vinyl aromatic polymers include decabromodiphenylethane and N,N-ethylene-bis(tetrabromophthalimide).

[0052] Process for forming flame-retardant compositions for wires and / or cables An embodiment of a process for forming a flame retardant composition for wires and / or cables, the process comprising: a first step of combining at least one polymer composition and at least one brominated flame retardant, wherein the brominated flame retardant is selected from a) a brominated styrene polymer having an aromatically bonded bromine and having a weight-average molecular weight of about 650 to about 75,000 and a bromine content of about 60 wt% or more, and / or b) a brominated anionic chain-transfer vinyl aromatic polymer containing about 70 wt% or more bromine, with at least one synergist; and then extruding the mixture from the first step to coat wires and / or cables.

[0053] A further embodiment of the process for forming a flame retardant composition, the process comprising a first step of combining at least one polymer composition and at least one organic peroxide, wherein the brominated flame retardant is selected from a) a brominated styrene polymer having an aromatically bonded bromine and having a weight-average molecular weight of about 650 to about 75,000 and a bromine content of about 60 wt% or more, and / or b) a brominated anionic chain-transfer vinyl aromatic polymer having about 70 wt% or more bromine. A further embodiment of the process for forming a flame retardant composition, comprising a first step of extruding the mixture from the first step to coat a wire and / or cable; and a third step of heating the coated wire and / or coated cable to a temperature above the decomposition point of at least one organic peroxide.

[0054] A further embodiment of the process for forming a flame retardant composition, the process comprising a first step of comprising at least one polymer composition, at least one synergistic agent, and at least one brominated flame retardant, wherein the brominated flame retardant contains aromatically bonded bromine, and a Further embodiments of a process for forming a flame retardant composition, comprising a first step of combining a brominated flame retardant with at least one brominated flame retardant 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 wt% or more, and / or a) a brominated anionic chain-transfer vinyl aromatic polymer containing about 70 wt% or more bromine. 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 coated cables with an electron beam at an effective dose.

[0055] Examples of 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 they can be subcombinations with a substrate or host polymer in appropriate proportions.

[0056] When a flame-retardant polyolefin composition is formed from a flame-retardant additive composition, the flame-retardant additive composition is typically about 40 wt% or more of the flame-retardant polyolefin composition, or about 40 wt% to about 80 wt% of the flame-retardant polyolefin composition, based on the total weight of the flame-retardant polyolefin composition.

[0057] 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 an 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 subdividing the solidified strands into granules or pellets, 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.

[0058] 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 material. 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 thermosetting formulations.

[0059] Formation of wire and / or cable sheathing In particular, these compositions of the present invention are useful as sheathing for wires and / or cables. Flame retardants are used in wire and / or cable formulations to meet the flame retardancy required for specific applications such as household appliances, building and construction, automotive cables, and solar power wires. In these applications, the insulating sheathing covering the conductor is made flame retardant by incorporating various flame retardant chemistry or techniques (Br, P, metal hydroxides, etc.). Such flame retardant chemistry is also used in sheathing (the layer on top of the insulating material) formulations. The insulating material or sheathing 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, polyurethane and chlorinated polyethylene may also be used as the base polymer. Polyolefins can usually be crosslinked by (a) moisture curing, (b) peroxide curing, or (c) electron beam curing techniques.

[0060] Typically, the composition is prepared in a compounding extruder where all components are mixed, uniformly distributed, and dispersed. The extruded compound is then formed into pellets. These pellets are then typically fed into a wireline extruder to coat the wires. In the case of thermosetting wires, coating The wires are crosslinked in a second step based on the chemical action of hardening.

[0061] Suitable curing chemical processes for the present invention include electron beam curing and peroxide curing. When curing with peroxide, the wire is passed through a continuous vulcanizing tube at high temperatures. When curing with an electron beam, the wire passes through an electron beam chamber.

[0062] In the case of peroxide curing, any process known in the art is suitable for this purpose. Typically, for example, the curing system may include an organic peroxide such as 2,5-dimethyl-2,5-di-(tert-butylperoxy)hexane, dicumyl peroxide, VUL-CUP®, or DiCup®, which is introduced into the blend at a temperature below the decomposition point of the peroxide, and crosslinking may include heating the blend to a temperature above the decomposition point of the peroxide. In one embodiment, crosslinking may include a continuous vulcanization process located downstream from the extruder. In another embodiment, crosslinking may include the Engel method, in which, after the introduction of the peroxide, the blend is pushed through a head maintained at a temperature above the decomposition temperature of the peroxide to form a crosslinked extruded product.

[0063] For electron beam curing, any process known in the art is suitable for this purpose. For example, this method may involve irradiating a flame retardant composition with an effective dose of electron beam irradiation. The effective dose or absorbed dose of electron beam irradiation is 49 to 201 kilojoules of energy (kJ / kg) per kilogram of EBC composition, or 49 to 160 kJ / kg, or 80 to 201 kJ / kg, or 80 to 160 kJ / kg, or 50 to 80 kJ / kg, or 100 to 140 kJ / kg, or 160 to 201 kJ / kg. 100 kJ / kg is equivalent to 10 megarads (Mrad) / kg, which is equivalent to 100,000 grays. 1 gray = 1 joule per kilogram (J / kg) = 100 rads. The electron beam irradiation step can be carried out in any suitable atmosphere, such as air or molecular nitrogen gas, at any suitable temperature, such as 10°C to 50°C (e.g., 23°C ± 1°C). Irradiation can be carried out continuously or intermittently. [Examples]

[0064] overview component The components used to prepare the flame-retardant composition are shown 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 practice of the present invention, known analytical methods can be used or adapted for use in analysis. Brominated flame retardants and / or, where applicable, the formed flame-retardant polyolefin compositions were measured using the following methods.

[0066] The analytical methods used or adapted for analyzing polymeric 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 by subjecting three or six samples of a specific insulated conductor to the UL2556 protocol. This involves applying a 125 mm flame at a 20° angle for 15 seconds to a 610 mm (24 inch) long vertically oriented test specimen five times. 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 layer of cotton 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 ± 0.1 inch) above the point where the tip of the blue inner cone of the flame strikes the test specimen. Position it 0.25 inches below. Failure of the test is based on one of the following criteria: 25% of the kraft paper tape flag burns, refined cotton ignites, or the test piece burns for more than 60 seconds with any of five flame applications. As an additional measure of flammability, the length of uncarbonized insulation ("length of uncarbonized portion to mark") is measured at the completion of the test. Ignition of VW-1 cotton indicates whether the falling material ignited the cotton bed.

[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 bromine are reported as wt%.

[0070] Example 1 The coated wire and / or cable formulations shown in Table 1 below were prepared according to the description contained herein. The wire structure used 14AWG tin-clad copper wire with 0.030-inch insulation. The brominated flame-retardant coated wire was fed through a 60-foot steam-filled steel pipe to complete the peroxide curing process. The cured cables were then used in the following tests. Table 1 shows the peroxide crosslinkable flame-retardant formulations. Example 1 uses a polymeric brominated flame retardant as disclosed herein. Comparison 1 contains the commercially available SAYTEX® 8010 small molecule brominated flame retardant. Example 2 uses the commercially available polymeric aromatic brominated flame retardant SAYTEX® HP3010. [Table 1]

[0071] Table 2 below shows various properties of peroxide-cured wires. [Table 2]

[0072] Example 2 A second embodiment of coated wires and / or cables was manufactured by electron beam curing. The wire structure used 14AWG copper wire with 0.030 inch insulation. Cured wires were manufactured by irradiating with electron beam curable flame retardant formulations (Table 3) at 20 Mrad. The cured cables were then used in the following tests. Table 3 shows various electron beam curable flame retardant formulations. Table 4 shows the wire extrusion conditions, die pressure readings, and wire surface quality. Comparison 1 is a commercially available SAYTEX®-8010 small molecule brominated flame retardant. Example 1 is a polymer brominated flame retardant prepared according to the disclosure contained herein. [Table 3] [Table 4] [Table 5]

[0073] The process conditions in Example 2 demonstrate the advantages of lowering the die pressure during wire extrusion while maintaining critical VW-1 and hot creep performance. Such improvements are important to customers due to the potential for reduced energy consumption and increased line speed (improved throughput).

[0074] Example 3 Examples of coated wires and / or cables were manufactured by electron beam curing. The wire structure used was 14AWG tin-clad copper wire with 0.030-inch insulation. Cured wires were manufactured by irradiating with electron beam-curable flame retardant formulations (Table 3) at 15 Mrad. The cured cables were then used in the following tests. Table 6 shows various electron beam-curable flame retardant formulations. Table 7 shows the wire extrusion conditions, die pressure readings, and wire surface quality. For comparison, the commercially available SAYTEX®-8010 small molecule brominated flame retardant is used. Examples 3-1 to 3-5 use polymer brominated flame retardants prepared according to the disclosures contained herein. [Table 6] [Table 7] [Table 8]

[0075] Example 4 Examples of coated wires and / or cables were manufactured by electron beam curing. The wire structure used was 14AWG tin-clad copper wire with 0.030-inch insulation. Cured wires were manufactured by irradiating with electron beam-curable flame retardant formulations (Table 3) at 15 Mrad. The cured cables were then used in the following tests. Table 9 shows various electron beam-curable flame retardant formulations. Table 10 shows the wire extrusion conditions, die pressure readings, and wire surface quality. For comparison, the commercially available SAYTEX®-8010 small molecule brominated flame retardant is used. In the examples, polymer brominated flame retardants prepared according to the disclosures contained herein are used. [Table 9] [Table 10] [Table 11]

[0076] Example 5 Examples of flame retardants and polypropylene compounds are shown below. These compounds were manufactured according to the disclosures contained herein. The above PP-BFR compounds were compounded in a 30 mm twin-screw extruder at 200°C and 175 rpm. The compounded material was cooled and pelletized. The wt% of BFR was adjusted to maintain a constant Br% (16.5) in each compound. [Table 12]

[0077] Example 6 Examples of coated wires and / or coated cables were manufactured and used from polypropylene cable insulation. This insulation was manufactured according to the disclosure contained herein. Each of the examples in Example 5 was used herein. Insulation of a 30 mil BFR-PP compound was extruded onto 14 AWG copper wire at a line rate of 5 meters / min using a 0.75-inch uniscrew extruder with a 3:1 Maddock screw head. The manufactured wires were analyzed. Note that the BFR of the present invention offers the following advantages, as can be seen in the table below. 1. A 30% lower die pressure results in better melt flow compared to non-polymeric BFRs. 2. Provides horizontal combustion performance compared to the commercially available S-8010 / BT-93W. 3. On the other hand, all BFRs provide crushing performance exceeding 10KN (the maximum limit of the device). The present invention provides even better crushing performance. [Table 13]

[0078] Example 7 Examples of coated wires and / or coated cables were manufactured and used with thermoplastic cable coatings. These coatings were manufactured according to the disclosures contained herein. TPU-BFR compounds were manufactured in a WP twin-screw extruder at 200°C and 200 rpm. High molecular weight BFRs and non-high molecular weight (S-8010, BT-93W) BFRs were used in the formulations, while maintaining a constant Br% (16.5%) and Br / ATO ratio. [Table 14]

[0079] Example 9 Examples of thermoplastic tapes were manufactured. TPU-FR pellets compounded on WP were dried at 100°C for 4 hours before tape production using a single-screw extruder. Tape was produced from the TPU-BFR compound. The conditions for the single-screw extruder used were a 0.75-inch single-screw extruder with a 2:1 PE screw, 160°C / 190°C / 190°C / 190°C, 20 / 40 / 20 screen pack, 45 rpm, and a tape thickness of 30 mils. As can be seen below, the BFR of the present invention provides better elongation at break and good tear strength than non-polymeric S-8010 while offering V2 combustion performance. [Table 15]

[0080] 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 certain components under the conditions required in accordance with this disclosure. Thus, this component is identified as the component that is brought together in connection with the performance of the desired operation or the formation of the 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 at the time immediately before it was first brought into contact with, blended, or mixed with one or more other substances, components, and / or components in accordance with this disclosure. Therefore, there is no substantial concern that any substance, component, or ingredient may have lost its original identity through a chemical reaction or transformation during the course of an operation of contact, blending, or mixing, provided that such operation is carried out in accordance with the present disclosure and the ordinary skill of a chemist.

[0081] The present invention may include, consist of, or essentially consist of the materials and / or procedures listed herein.

[0082] 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.

[0083] 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.

[0084] 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. At least one polymer composition, At least one brominated flame retardant, At least one synergistic agent in an amount exceeding approximately 0.0 wt%, A flame-retardant composition for wires and / or cables, comprising: The aforementioned brominated flame retardant contains bromine bonded to an aromatic compound, and a) Brominated styrene polymers having a weight-average molecular weight of approximately 650 to approximately 75,000 and a bromine content of approximately 60 wt% or more, and / or b) A brominated anionic chain-transfer vinyl aromatic polymer having a weight-average molecular weight of approximately 650 to approximately 75,000 and containing approximately 70 wt% or more of bromine. The flame retardant composition selected from the above.

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 anionic chain-transfer vinyl aromatic polymer containing about 70 wt% or more bromine, preferably about 72 wt% or more, and a weight-average molecular weight of about 1000 or more, preferably about 1250 or more.

4. The flame retardant composition according to claim 1, wherein the brominated flame retardant has a bromine content of about 67 wt% or more, more preferably about 68 wt% 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 a polyolefin such as polyethylene, and polyolefin copolymers such as poly(ethylene-vinyl acetate) (EVA) and poly(ethylene ethyl acrylate) (EEA), along with a derivative of a polyolefin such as chlorinated polyethylene or silane-functionalized polyethylene.

7. The flame retardant composition according to any one of claims 1 to 6, further comprising an organic peroxide.

8. The flame retardant composition according to claim 7, wherein the organic peroxide comprises dicumyl peroxide or 2,5-dimethyl-2,5-di-(tert-butylperoxy)hexane.

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 coated cable, wherein the coating is made of a flame-retardant composition described in any of the prior claims.

11. A process for forming a flame-retardant composition for wires and / or cables, wherein the process comprises: The first step is, i. At least one polymer composition and ii. At least one brominated flame retardant, wherein the brominated flame retardant contains aromatically bonded bromine, and 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 wt% or more, and / or b) about 70 wt% The above-mentioned brominated anionic chain-transfer vinyl aromatic polymers containing bromine, comprising at least one brominated flame retardant selected from these, iii. At least one synergistic agent, The first step includes combining, A second step of extruding the mixture from the first step in order to cover wires and / or cables, A process for forming the flame-retardant composition, including the following:

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

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

15. A process for forming a 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) The first step, i. At least one polymer composition and ii. At least one synergistic agent, iii. At least one brominated flame retardant, wherein the brominated flame retardant contains aromatically bonded 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 wt% or more, and / or b) a brominated anionic chain-transfer vinyl aromatic polymer containing about 70 wt% or more bromine, iv. At least one organic peroxide, The first step includes combining, (b) A second step of extruding the mixture from the first step in order to cover a wire and / or cable, (c) A third step of heating the coated wire and / or the coated cable to a temperature above the decomposition point of the at least one organic peroxide, A process for forming the flame-retardant composition, including the following:

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

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

20. A process for forming a flame retardant composition according to any one of claims 16 to 19, wherein the synergistic agent comprises antimony oxide.

21. A process for forming a flame retardant composition according to any one of claims 16 to 20, wherein the organic peroxide comprises dicumyl peroxide or 2,5-dimethyl-2,5-di-(tert-butylperoxy)hexane.

22. A process for forming a flame-retardant composition, wherein the process comprises: (a) The first step, i. At least one polymer composition and ii. At least one synergistic agent, iii. At least one brominated flame retardant, wherein the brominated flame retardant contains aromatically bonded 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 wt% or more, and / or b) a brominated anionic chain-transfer vinyl aromatic polymer containing about 70 wt% or more bromine, The first step includes combining, (b) A second step of extruding the mixture from the first step in order to cover a wire and / or cable, (c) A third step of irradiating the mixture of the coated wire and / or the coated cable with an electron beam at an effective dose, A process for forming the flame-retardant composition, including the following:

23. A process for forming a flame retardant composition according to claim 22, 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.

24. The process for forming a flame retardant composition according to claim 22, wherein the brominated flame retardant is a brominated anionic chain-transfer vinyl aromatic polymer containing about 70 wt% or more bromine, preferably about 72 wt% or more, and a weight-average molecular weight of about 1000 or more, preferably about 1250 or more.

25. A process for forming a flame retardant composition according to claim 22, wherein the brominated flame retardant has a bromine content of about 67 wt% or more, more preferably about 68 wt% or more.

26. A process for forming a flame retardant composition according to any one of claims 22 to 25, wherein the synergistic agent comprises antimony oxide.

27. A coated wire and / or coated cable, wherein the coating comprises a flame-retardant composition produced from a process according to any one of claims 11 to 26.

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