Char-forming polymer, moldable composition and method

Claim 2

A char-forming polymer which consists essentially of: (A) from about 2.5 to about 50 mol percent recurring units of at least one monomer which is capable of undergoing tautomerization and has the general formula: ##STR5## wherein R 1 represents a hydrogen atom, or a C 1 to C 5 alkyl group; R 2 represents a carboxylic acid group, and amide group or a C 1 to C 5 N-mono-or di-substituted amide group; and, wherein R 3 represents an N mono-substituted amide group in which the substituent can be a hydrogen atom, a C 1 to C 5 alkyl group, an aryl group or an amide group; (B) from about 2.5 to about 50 mol percent recurring units of at least one monomer which is capable of undergoing a nucleophilic substitution reaction by (A) and has the general formula: ##STR6## wherein R 1 , is as defined above; R 4 represents a hydrogen atom; and, R 5 represents a phosphonate or substituted phosphonate group bearing a leaving group or an aryl or substituted aryl group bearing a leaving group; and (C) from about 0 to about 95 mol percent recurring units of at least one monomer which is copolymerizable with (A) and (B) and has the general formula: ##STR7## wherein R 1 is as defined above; R 6 represents an aryl or substituted aryl group or ##STR8## and wherein R 7 represents a C 1 to C 15 alkyl group or an aryl or substituted aryl group.

Claim 3

The char-forming polymer of claim 1 in which in the general formula for said (A) monomer, R 2 and R 3 taken together represent an N-substituted imide linkage, in which the substituent is a hydrogen atom or an amide group with the proviso, that if R 2 and R 3 taken together represent a maleimide linkage, then (B) monomer cannot solely be a vinyl phosphonate monomer.

Claim 4

The char-forming polymer of claim 1 or 2 in which in the general formula for said (B) monomer R 4 and R 5 taken together represent an N-substituted imide linkage, wherein the substituent on the imide linkage is R 5 as defined above.

Claim 5

The char-forming random polymer of claims 1, 2 or 3 in which said leaving group is a weak base whose conjugate acid has a pK a value of 5 or less.

Claim 6

A moldable composition comprising a thermoplastic resin and a char-forming amount of a char-forming polymer which contains: (A) from about 2.5 to about 50 mol percent recurring units of at least one monomer which is capable of undergoing tautomerization and has the general formula: ##STR9## wherein R 1 represents a hydrogen atom, or a C 1 to C 5 alkyl group; R 2 represents a carboxylic acid group, and amide group or a C 1 to C 5 N-mono-or di-substituted amide group; and, wherein R 3 represents an N mono-substituted amide group in which the substituent can be a hydrogen atom, a C 1 to C 5 alkyl group, an aryl group or an amide group; (B) from about 2.5 to about 50 mol percent recurring units of at least one monomer which is capable of undergoing a nucleophilic substitution reaction by (A) and has the general formula: ##STR10## wherein R 1 , is as defined above; R 4 represents a hydrogen atom; and, R 5 represents a phosphonate or substituted phosphonate group bearing a leaving group or an aryl or substituted aryl group bearing a leaving group; and (C) from about 0 to about 95 mol percent recurring units of at least one monomer which is copolymerizable with (A) and (B) and has the general formula: ##STR11## wherein R 1 is as defined above; R 6 represents an aryl or substituted aryl group or ##STR12## and wherein R 7 represents a C 1 to C 15 alkyl group or an aryl or substituted aryl group.

Claim 7

A moldable composition comprising a thermoplastic resin and a char-forming amount of a char-forming polymer which contains: (A) from about 2.5 to about 50 mol percent recurring units of at least one monomer which is capable of undergoing tautomerization and has the general formula: ##STR9## wherein R 1 represents a hydrogen atom, or a C 1 to C 5 alkyl group; R 2 represents a carboxylic acid group, and amide group or a C 1 to C 5 N-mono-or di-substituted amide group; and, wherein R 3 represents an N mono-substituted amide group in which the substituent can be a hydrogen atom, a C 1 to C 5 alkyl group, an aryl group or an amide group; (B) from about 2.5 to about 50 mol percent recurring units of at least one monomer which is capable of undergoing a nucleophilic substitution reaction by (A) and has the general formula: ##STR10## wherein R 1 , is as defined above; R 4 represents a hydrogen atom; and, R 5 represents a phosphonate or substituted phosphonate group bearing a leaving group or an aryl or substituted aryl group bearing a leaving group; and (C) from about 0 to about 95 mol percent recurring units of at least one monomer which is copolymerizable with (A) and (B) and has the general formula: ##STR11## wherein R 1 is as defined above; R 6 represents an aryl or substituted aryl group or ##STR12## and wherein R 7 represents a C 1 to C 15 alkyl group or an aryl or substituted aryl group.

Claim 8

The molding composition of claim 5 in which in the general formula for said (A) monomer, R 2 and R 3 taken together represent an N-substituted imide linkage, in which the substituent is a hydrogen atom or an amide group with the proviso, if R 2 and R 3 taken together represent a maleimide linkage then (B) monomer cannot solely be a vinyl phosphonate monomer.

Claim 9

The molding composition of claims 5 or 6 in which in the general formula for said (B) monomer, R 4 and R 5 taken together represent an N-substituted imide linkage wherein the substituent on the imide linkage is R 5 as defined above.

Claim 10

The molding composition of claim 5 in which said thermoplastic resin is polycarbonate.

Claim 11

The molding composition of claim 5 in which said thermoplastic resin is nylon.

Claim 12

The molding composition of claim 5 in which said thermoplastic resin is polyethylene terephthlate.

Claim 13

The molding composition of claim 5 in which said thermoplastic resin is styrene/maleic anhydride.

Claim 14

The molding composition of claim 5 in which said thermoplastic resin is styrene/acrylonitrile.

Claim 15

A method for increasing the char residue formation of molded compositions upon combustion which method comprises incorporating into the molding composition before molding a char-forming amount of the char-forming polymer of claim 1.

Claim 16

A method for increasing the char residue formation of molded compositions upon combustion which method comprises incorporating into the molding composition before molding a char-forming amount of the char-forming polymer of claim 2.

Claim 17

A method for increasing the char residue formation of molded compositions upon combustion which method comprises incorporating into the molding composition before molding, a char-forming amount of the char-forming polymer of claim 3.

Claim 18

A method for producing a molded composition which comprises forming a molding composition which comprises a char-forming amount of the char-forming polymer of claim 1 and molding the resulting composition.

Claim 19

A method for producing a molded composition which comprises forming a molding composition which comprises a char-forming amount of the char-forming polymer of claim 2 and molding the resulting composition.

Claim 20

A method for producing a molded composition which comprises forming a molding composition which comprises a char-forming amount of the char-forming polymer of claim 3 and molding the resulting composition.

Claim 21

A char forming polymer which consists essentially of: (A) from about 2.5 to about 50 mol percent recurring units of a monomer which is capable of undergoing tautomerization selected from the group consisting of: N-carbamyl maleimide, maleamic acid, acrylamide, methacrylamide N-carbamyl maleamic acid, n-hexyl maleamic acid, maleamic acid diamine, N-carbamyl acrylamide, N-carbamyl methacrylamide, N-methyl acrylamide, maleimide, N-phenyl methacrylamide, N-methyl maleamic acid, and N-phenyl maleamic acid; (B) from about 2.5 to about 50 mol percent recurring units of a monomer which is capable of undergoing a neucleophilic substitution reaction by (A) and selected from the group consisting of: dibromostyrene, monobromostyrene, tribromostyrene, bis(beta-chloroethyl) vinyl phosphonate, N-(Tribromophenyl)maleimide, N-monobromo phenyl)malemide, N-(dibromo phenyl)maleimide, tosyl styrene, mesyl styrene, dibromo α-methyl styrene, dibromo methyl styrene, bis(beta-bromoethyl) vinyl phosphonate, N-(tosyl phenyl)maleimide, vinyl benzyl chloride, brosyl styrene, and N-chloroethyl)maleimide; and (C) from about 0 to about 95 mole percent recurring units of a monomer which is copolymerizable with (A) and (B) and is selected from the group consisting of: styrene, α-methyl styrene, α-ethyl styrene, p-methyl styrene, t-butyl styrene, methyl acrylate, n-butyl acrylate, methyl methacrylate, n-butyl methacrylate, norbornyl acrylate, norbornyl methacrylate, phenyl acrylate, phenyl methacrylate, isobutyl methacrylate and isobornyl methacrylate; with the proviso that if (A) is either N-carbamyl maleimide or maleimide then (B) cannot solely be a vinyl phosphonate monomer.

Claim 22

A char forming polymer which consists essentially of: (A) from about 2.5 to about 50 mol percent recurring units of a monomer which is capable of undergoing tautomerization selected from the group consisting of: N-carbamyl maleimide, maleamic acid, acrylamide, methacrylamide N-carbamyl maleamic acid, n-hexyl maleamic acid, maleamic acid diamine, N-carbamyl acrylamide, N-carbamyl methacrylamide, N-methyl acrylamide, maleimide, N-phenyl methacrylamide, N-methyl maleamic acid, and N-phenyl maleamic acid; (B) from about 2.5 to about 50 mol percent recurring units of a monomer which is capable of undergoing a neucleophilic substitution reaction by (A) and selected from the group consisting of: dibromostyrene, monobromostyrene, tribromostyrene, bis(beta-chloroethyl) vinyl phosphonate, N-(Tribromophenyl)maleimide, N-monobromo phenyl)malemide, N-(dibromo phenyl)maleimide, tosyl styrene, mesyl styrene, dibromo α-methyl styrene, dibromo methyl styrene, bis(beta-bromoethyl) vinyl phosphonate, N-(tosyl phenyl)maleimide, vinyl benzyl chloride, brosyl styrene, and N-chloroethyl)maleimide; and (C) from about 0 to about 95 mole percent recurring units of a monomer which is copolymerizable with (A) and (B) and is selected from the group consisting of: styrene, α-methyl styrene, α-ethyl styrene, p-methyl styrene, t-butyl styrene, methyl acrylate, n-butyl acrylate, methyl methacrylate, n-butyl methacrylate, norbornyl acrylate, norbornyl methacrylate, phenyl acrylate, phenyl methacrylate, isobutyl methacrylate and isobornyl methacrylate; with the proviso that if (A) is either N-carbamyl maleimide or maleimide then (B) cannot solely be a vinyl phosphonate monomer.