WO2018185180A1 - Composition de polymère ignifuge - Google Patents
Composition de polymère ignifuge Download PDFInfo
- Publication number
- WO2018185180A1 WO2018185180A1 PCT/EP2018/058638 EP2018058638W WO2018185180A1 WO 2018185180 A1 WO2018185180 A1 WO 2018185180A1 EP 2018058638 W EP2018058638 W EP 2018058638W WO 2018185180 A1 WO2018185180 A1 WO 2018185180A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- flame
- polymer composition
- retardant polymer
- μηη
- retardant
- Prior art date
Links
- 239000003063 flame retardant Substances 0.000 title claims abstract description 193
- 229920000642 polymer Polymers 0.000 title claims abstract description 192
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 title claims abstract description 189
- 239000000203 mixture Substances 0.000 title claims abstract description 171
- 229910052500 inorganic mineral Inorganic materials 0.000 claims abstract description 193
- 239000011707 mineral Substances 0.000 claims abstract description 193
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- 239000000454 talc Substances 0.000 claims description 56
- 229910052623 talc Inorganic materials 0.000 claims description 56
- 238000000034 method Methods 0.000 claims description 27
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 19
- 239000010451 perlite Substances 0.000 claims description 19
- 235000019362 perlite Nutrition 0.000 claims description 19
- -1 polyethylene Polymers 0.000 claims description 15
- 239000010456 wollastonite Substances 0.000 claims description 14
- 229910052882 wollastonite Inorganic materials 0.000 claims description 14
- 229910052618 mica group Inorganic materials 0.000 claims description 12
- HPTYUNKZVDYXLP-UHFFFAOYSA-N aluminum;trihydroxy(trihydroxysilyloxy)silane;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O[Si](O)(O)O HPTYUNKZVDYXLP-UHFFFAOYSA-N 0.000 claims description 11
- 229910052621 halloysite Inorganic materials 0.000 claims description 11
- 239000010445 mica Substances 0.000 claims description 11
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 claims description 8
- 239000000347 magnesium hydroxide Substances 0.000 claims description 7
- 229910001862 magnesium hydroxide Inorganic materials 0.000 claims description 7
- 239000004698 Polyethylene Substances 0.000 claims description 6
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical group [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 6
- 229910021502 aluminium hydroxide Inorganic materials 0.000 claims description 6
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 claims description 6
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 6
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 6
- 239000000945 filler Substances 0.000 claims description 5
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 claims description 5
- 229920002689 polyvinyl acetate Polymers 0.000 claims description 5
- 239000011118 polyvinyl acetate Substances 0.000 claims description 5
- 239000005909 Kieselgur Substances 0.000 claims description 4
- 239000005350 fused silica glass Substances 0.000 claims description 4
- CXUJOBCFZQGUGO-UHFFFAOYSA-F calcium trimagnesium tetracarbonate Chemical compound [Mg++].[Mg++].[Mg++].[Ca++].[O-]C([O-])=O.[O-]C([O-])=O.[O-]C([O-])=O.[O-]C([O-])=O CXUJOBCFZQGUGO-UHFFFAOYSA-F 0.000 claims description 3
- 229910021485 fumed silica Inorganic materials 0.000 claims description 3
- 229910000515 huntite Inorganic materials 0.000 claims description 3
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 claims description 3
- 239000004114 Ammonium polyphosphate Substances 0.000 claims description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- 239000004115 Sodium Silicate Substances 0.000 claims description 2
- 235000019826 ammonium polyphosphate Nutrition 0.000 claims description 2
- 229920001276 ammonium polyphosphate Polymers 0.000 claims description 2
- 239000010439 graphite Substances 0.000 claims description 2
- 229910002804 graphite Inorganic materials 0.000 claims description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 2
- SHFGJEQAOUMGJM-UHFFFAOYSA-N dialuminum dipotassium disodium dioxosilane iron(3+) oxocalcium oxomagnesium oxygen(2-) Chemical compound [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[Na+].[Na+].[Al+3].[Al+3].[K+].[K+].[Fe+3].[Fe+3].O=[Mg].O=[Ca].O=[Si]=O SHFGJEQAOUMGJM-UHFFFAOYSA-N 0.000 claims 1
- 239000002245 particle Substances 0.000 description 51
- 239000000463 material Substances 0.000 description 13
- 230000008569 process Effects 0.000 description 12
- 238000012360 testing method Methods 0.000 description 10
- 239000000654 additive Substances 0.000 description 9
- 238000013329 compounding Methods 0.000 description 9
- 239000007789 gas Substances 0.000 description 8
- 239000000779 smoke Substances 0.000 description 8
- 239000000725 suspension Substances 0.000 description 8
- 239000003795 chemical substances by application Substances 0.000 description 7
- 239000011575 calcium Substances 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 5
- 238000000227 grinding Methods 0.000 description 5
- 229910052749 magnesium Inorganic materials 0.000 description 5
- 239000011777 magnesium Substances 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 230000004888 barrier function Effects 0.000 description 4
- 229910052791 calcium Inorganic materials 0.000 description 4
- 230000015556 catabolic process Effects 0.000 description 4
- 238000006731 degradation reaction Methods 0.000 description 4
- 235000014113 dietary fatty acids Nutrition 0.000 description 4
- 239000000194 fatty acid Substances 0.000 description 4
- 229930195729 fatty acid Natural products 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
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- 239000011236 particulate material Substances 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 229910052708 sodium Inorganic materials 0.000 description 4
- 239000011734 sodium Substances 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 239000005995 Aluminium silicate Substances 0.000 description 3
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 3
- 235000012211 aluminium silicate Nutrition 0.000 description 3
- 230000033228 biological regulation Effects 0.000 description 3
- 238000007385 chemical modification Methods 0.000 description 3
- 229910052681 coesite Inorganic materials 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 229910052906 cristobalite Inorganic materials 0.000 description 3
- 230000032798 delamination Effects 0.000 description 3
- 238000010790 dilution Methods 0.000 description 3
- 239000012895 dilution Substances 0.000 description 3
- 239000002270 dispersing agent Substances 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 150000004665 fatty acids Chemical class 0.000 description 3
- 239000004615 ingredient Substances 0.000 description 3
- 238000009413 insulation Methods 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000011159 matrix material Substances 0.000 description 3
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 3
- 229910052700 potassium Inorganic materials 0.000 description 3
- 238000004062 sedimentation Methods 0.000 description 3
- 229910052682 stishovite Inorganic materials 0.000 description 3
- 229910052905 tridymite Inorganic materials 0.000 description 3
- OWICEWMBIBPFAH-UHFFFAOYSA-N (3-diphenoxyphosphoryloxyphenyl) diphenyl phosphate Chemical compound C=1C=CC=CC=1OP(OC=1C=C(OP(=O)(OC=2C=CC=CC=2)OC=2C=CC=CC=2)C=CC=1)(=O)OC1=CC=CC=C1 OWICEWMBIBPFAH-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 238000004438 BET method Methods 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 239000004594 Masterbatch (MB) Substances 0.000 description 2
- 229920000388 Polyphosphate Polymers 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- 235000021355 Stearic acid Nutrition 0.000 description 2
- YSMRWXYRXBRSND-UHFFFAOYSA-N TOTP Chemical compound CC1=CC=CC=C1OP(=O)(OC=1C(=CC=CC=1)C)OC1=CC=CC=C1C YSMRWXYRXBRSND-UHFFFAOYSA-N 0.000 description 2
- 241000276425 Xiphophorus maculatus Species 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 2
- 229910000323 aluminium silicate Inorganic materials 0.000 description 2
- LJCFOYOSGPHIOO-UHFFFAOYSA-N antimony pentoxide Chemical compound O=[Sb](=O)O[Sb](=O)=O LJCFOYOSGPHIOO-UHFFFAOYSA-N 0.000 description 2
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 2
- 239000003963 antioxidant agent Substances 0.000 description 2
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 2
- 229910001919 chlorite Inorganic materials 0.000 description 2
- 229910052619 chlorite group Inorganic materials 0.000 description 2
- QBWCMBCROVPCKQ-UHFFFAOYSA-N chlorous acid Chemical compound OCl=O QBWCMBCROVPCKQ-UHFFFAOYSA-N 0.000 description 2
- 238000000748 compression moulding Methods 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 230000001186 cumulative effect Effects 0.000 description 2
- VONWDASPFIQPDY-UHFFFAOYSA-N dimethyl methylphosphonate Chemical compound COP(C)(=O)OC VONWDASPFIQPDY-UHFFFAOYSA-N 0.000 description 2
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 2
- 239000010459 dolomite Substances 0.000 description 2
- 229910000514 dolomite Inorganic materials 0.000 description 2
- 238000000605 extraction Methods 0.000 description 2
- 238000001746 injection moulding Methods 0.000 description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 2
- HQKMJHAJHXVSDF-UHFFFAOYSA-L magnesium stearate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O HQKMJHAJHXVSDF-UHFFFAOYSA-L 0.000 description 2
- 229920001910 maleic anhydride grafted polyolefin Polymers 0.000 description 2
- 229910052748 manganese Inorganic materials 0.000 description 2
- 239000011572 manganese Substances 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 239000005306 natural glass Substances 0.000 description 2
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 2
- 150000002896 organic halogen compounds Chemical class 0.000 description 2
- NFHFRUOZVGFOOS-UHFFFAOYSA-N palladium;triphenylphosphane Chemical compound [Pd].C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1 NFHFRUOZVGFOOS-UHFFFAOYSA-N 0.000 description 2
- 239000001205 polyphosphate Substances 0.000 description 2
- 235000011176 polyphosphates Nutrition 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000010791 quenching Methods 0.000 description 2
- 230000000171 quenching effect Effects 0.000 description 2
- 239000011343 solid material Substances 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 239000008117 stearic acid Substances 0.000 description 2
- 238000004381 surface treatment Methods 0.000 description 2
- ASLWPAWFJZFCKF-UHFFFAOYSA-N tris(1,3-dichloropropan-2-yl) phosphate Chemical compound ClCC(CCl)OP(=O)(OC(CCl)CCl)OC(CCl)CCl ASLWPAWFJZFCKF-UHFFFAOYSA-N 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- DJKGDNKYTKCJKD-BPOCMEKLSA-N (1s,4r,5s,6r)-1,2,3,4,7,7-hexachlorobicyclo[2.2.1]hept-2-ene-5,6-dicarboxylic acid Chemical class ClC1=C(Cl)[C@]2(Cl)[C@H](C(=O)O)[C@H](C(O)=O)[C@@]1(Cl)C2(Cl)Cl DJKGDNKYTKCJKD-BPOCMEKLSA-N 0.000 description 1
- BZQKBFHEWDPQHD-UHFFFAOYSA-N 1,2,3,4,5-pentabromo-6-[2-(2,3,4,5,6-pentabromophenyl)ethyl]benzene Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1CCC1=C(Br)C(Br)=C(Br)C(Br)=C1Br BZQKBFHEWDPQHD-UHFFFAOYSA-N 0.000 description 1
- JYEUMXHLPRZUAT-UHFFFAOYSA-N 1,2,3-triazine Chemical compound C1=CN=NN=C1 JYEUMXHLPRZUAT-UHFFFAOYSA-N 0.000 description 1
- DEIGXXQKDWULML-UHFFFAOYSA-N 1,2,5,6,9,10-hexabromocyclododecane Chemical compound BrC1CCC(Br)C(Br)CCC(Br)C(Br)CCC1Br DEIGXXQKDWULML-UHFFFAOYSA-N 0.000 description 1
- VEORPZCZECFIRK-UHFFFAOYSA-N 3,3',5,5'-tetrabromobisphenol A Chemical compound C=1C(Br)=C(O)C(Br)=CC=1C(C)(C)C1=CC(Br)=C(O)C(Br)=C1 VEORPZCZECFIRK-UHFFFAOYSA-N 0.000 description 1
- 241000234282 Allium Species 0.000 description 1
- 235000002732 Allium cepa var. cepa Nutrition 0.000 description 1
- BTBUEUYNUDRHOZ-UHFFFAOYSA-N Borate Chemical compound [O-]B([O-])[O-] BTBUEUYNUDRHOZ-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- UDHXJZHVNHGCEC-UHFFFAOYSA-N Chlorophacinone Chemical compound C1=CC(Cl)=CC=C1C(C=1C=CC=CC=1)C(=O)C1C(=O)C2=CC=CC=C2C1=O UDHXJZHVNHGCEC-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- UAUDZVJPLUQNMU-UHFFFAOYSA-N Erucasaeureamid Natural products CCCCCCCCC=CCCCCCCCCCCCC(N)=O UAUDZVJPLUQNMU-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical group [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004696 Poly ether ether ketone Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004693 Polybenzimidazole Substances 0.000 description 1
- 239000004695 Polyether sulfone Substances 0.000 description 1
- 239000004697 Polyetherimide Substances 0.000 description 1
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- 239000004614 Process Aid Substances 0.000 description 1
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 1
- QHWKHLYUUZGSCW-UHFFFAOYSA-N Tetrabromophthalic anhydride Chemical compound BrC1=C(Br)C(Br)=C2C(=O)OC(=O)C2=C1Br QHWKHLYUUZGSCW-UHFFFAOYSA-N 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
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- 238000007792 addition Methods 0.000 description 1
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- PZZYQPZGQPZBDN-UHFFFAOYSA-N aluminium silicate Chemical compound O=[Al]O[Si](=O)O[Al]=O PZZYQPZGQPZBDN-UHFFFAOYSA-N 0.000 description 1
- 229910052787 antimony Inorganic materials 0.000 description 1
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 1
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- 239000012736 aqueous medium Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
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- 229910052792 caesium Inorganic materials 0.000 description 1
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- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- ZCZLQYAECBEUBH-UHFFFAOYSA-L calcium;octadec-9-enoate Chemical compound [Ca+2].CCCCCCCCC=CCCCCCCCC([O-])=O.CCCCCCCCC=CCCCCCCCC([O-])=O ZCZLQYAECBEUBH-UHFFFAOYSA-L 0.000 description 1
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- WHHGLZMJPXIBIX-UHFFFAOYSA-N decabromodiphenyl ether Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1OC1=C(Br)C(Br)=C(Br)C(Br)=C1Br WHHGLZMJPXIBIX-UHFFFAOYSA-N 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
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- BICAGYDGRXJYGD-UHFFFAOYSA-N hydrobromide;hydrochloride Chemical compound Cl.Br BICAGYDGRXJYGD-UHFFFAOYSA-N 0.000 description 1
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- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
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- 238000002356 laser light scattering Methods 0.000 description 1
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- 229910003002 lithium salt Inorganic materials 0.000 description 1
- 159000000002 lithium salts Chemical class 0.000 description 1
- HGPXWXLYXNVULB-UHFFFAOYSA-M lithium stearate Chemical compound [Li+].CCCCCCCCCCCCCCCCCC([O-])=O HGPXWXLYXNVULB-UHFFFAOYSA-M 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000002932 luster Substances 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
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- 235000019359 magnesium stearate Nutrition 0.000 description 1
- 239000002609 medium Substances 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- VUZPPFZMUPKLLV-UHFFFAOYSA-N methane;hydrate Chemical compound C.O VUZPPFZMUPKLLV-UHFFFAOYSA-N 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052627 muscovite Inorganic materials 0.000 description 1
- GKTNLYAAZKKMTQ-UHFFFAOYSA-N n-[bis(dimethylamino)phosphinimyl]-n-methylmethanamine Chemical compound CN(C)P(=N)(N(C)C)N(C)C GKTNLYAAZKKMTQ-UHFFFAOYSA-N 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 229910001682 nordstrandite Inorganic materials 0.000 description 1
- 150000004045 organic chlorine compounds Chemical class 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 238000003921 particle size analysis Methods 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- ACVYVLVWPXVTIT-UHFFFAOYSA-M phosphinate Chemical compound [O-][PH2]=O ACVYVLVWPXVTIT-UHFFFAOYSA-M 0.000 description 1
- UEZVMMHDMIWARA-UHFFFAOYSA-M phosphonate Chemical compound [O-]P(=O)=O UEZVMMHDMIWARA-UHFFFAOYSA-M 0.000 description 1
- 150000003014 phosphoric acid esters Chemical class 0.000 description 1
- 229910052615 phyllosilicate Inorganic materials 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920000747 poly(lactic acid) Polymers 0.000 description 1
- 229920002627 poly(phosphazenes) Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920001281 polyalkylene Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920002480 polybenzimidazole Polymers 0.000 description 1
- 229920002577 polybenzoxazole Polymers 0.000 description 1
- 229920001748 polybutylene Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920006393 polyether sulfone Polymers 0.000 description 1
- 229920002530 polyetherether ketone Polymers 0.000 description 1
- 229920001601 polyetherimide Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000004626 polylactic acid Substances 0.000 description 1
- 238000010094 polymer processing Methods 0.000 description 1
- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 229920001290 polyvinyl ester Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000007017 scission Effects 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 238000007560 sedimentation technique Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- 238000002444 silanisation Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000012748 slip agent Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000012756 surface treatment agent Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- XZZNDPSIHUTMOC-UHFFFAOYSA-N triphenyl phosphate Chemical compound C=1C=CC=CC=1OP(OC=1C=CC=CC=1)(=O)OC1=CC=CC=C1 XZZNDPSIHUTMOC-UHFFFAOYSA-N 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
- C08K3/016—Flame-proofing or flame-retarding additives
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
- C08K3/36—Silica
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/22—Expanded, porous or hollow particles
- C08K7/24—Expanded, porous or hollow particles inorganic
Definitions
- the present invention relates generally to flame-retardant polymer compositions comprising a polymer, a flame retardant, a high aspect ratio particulate mineral and an intumescent particulate mineral.
- the present invention further relates to articles comprising or made from said flame-retardant polymer compositions and methods of making said flame-retardant polymer compositions and said articles.
- a flame- retardant polymer composition comprising a polymer, a flame retardant, a high aspect ratio particulate mineral and an intumescent particulate mineral.
- an article made from or comprising a flame-retardant polymer composition according to any aspect or embodiment of the present invention is provided.
- the article is a cable covered with a flame-retardant polymer composition according to any aspect or embodiment of the present invention.
- a method of making a flame-retardant polymer composition comprising mixing the polymer, the flame retardant, the high aspect ratio particulate mineral and the intumescent mineral.
- the polymer is polyethylene, polyvinyl acetate, ethylene vinyl acetate or a combination thereof.
- the flame retardant is aluminium hydroxide (ATH), magnesium hydroxide (MDH) or a combination thereof.
- the high aspect ratio particulate mineral is talc, mica, wollastonite, halloysite or a combination of one or more thereof.
- the intumescent particulate material is perlite. In certain embodiments, the intumescent particulate mineral is unexpanded perlite.
- good flame-retardancy properties e.g. good or reduced heat release, smoke production, flame spread, vertical flame propagation, smoke density, smoke acidity and melt viscosity
- a flame-retardant polymer composition comprising a polymer, a flame retardant, a high aspect ratio particulate mineral and an intumescent particulate mineral.
- the flame-retardant polymer composition consists essentially of a polymer, a flame retardant, a high aspect ratio particulate mineral, an intumescent particulate mineral and optionally a siliceous mineral.
- the flame-retardant polymer composition consists of a polymer, a flame retardant, a high aspect ratio particulate mineral, an intumescent particulate mineral and optionally a siliceous mineral.
- the term “consisting essentially of” may, for example, exclude an additional element, step or ingredient not explicitly recited unless the additional element, step or ingredient does not materially affect the basic and novel properties of the invention.
- the total amount of the additional component(s) in the composition may, for example, be limited to 10 wt%.
- the total amount of the additional component(s) in the composition may be limited to 9 wt% or 8 wt% or 7 wt% or 6 wt% or 5 wt% or 4 wt% or 3 wt% or 2 wt% or 1 wt%.
- the polymer may, for example, be a thermoplastic polymer.
- the polymer may, for example, be present in the form of a polymer matrix.
- the other components of the flame-retardant polymer composition e.g. the flame retardant, the lamellar particulate mineral, the intumescent particulate mineral
- the polymer may, for example, be polyalkylene (e.g.
- the polymer is polyethylene, polyvinyl acetate, ethylene vinyl acetate or a combination of two or more thereof.
- the present invention may tend to be discussed in terms of a blend of ethylene vinyl acetate and polyethylene. However, the present invention should not be construed as being limited to such embodiment.
- the polymer may, for example, be present in the flame-retardant polymer composition in an amount of at least about 30 % based on the total weight of the flame-retardant polymer composition.
- the polymer may be present in the flame-retardant polymer composition in an amount of at least about 35 wt% or at least about 40 wt% or at least about 45 wt% or at least about 50 wt% or at least about 55 wt% or at least about 60 wt% based on the total weight of the flame-retardant polymer composition.
- the polymer may, for example, be present in the flame-retardant polymer composition in an amount up to about 80 wt%, for example up to about 75 wt%, for example up to about 70 wt%, for example up to about 65 wt% based on the total weight of the flame- retardant polymer composition.
- the polymer may, for example, be present in the flame- retardant polymer composition in an amount ranging from about 30 wt% to about 80 wt% or from about 30 wt% to about 70 wt% or from about 30 wt% to about 60 wt% or from about 40 wt% to about 80 wt% or from about 40 wt% to about 70 wt% or from about 40 wt% to about 60 wt% based on the total weight of the flame-retardant polymer composition.
- flame retardant refers to any chemical that, when added to a polymer, can prevent fire, inhibit or delay the spread of fire and/or limit the damage caused by fire.
- the flame retardant may, for example, work by one or more of endothermic degradation, thermal shielding, dilution of gas phase and gas phase radical quenching. Flame retardants that work by endothermic degradation remove heat from the substrate and thus cool the material. Flame retardants that work by thermal shielding create a thermal insulation barrier between the burning and unburned parts of the material, for example by forming a char, which separates the flame from the material and slows heat transfer to the unburned material. Flame retardants that work by dilution of the gas phase produce inert gases (e.g. carbon dioxide and/or water) by thermal degradation and thus dilute the combustible gases, thus lowering the partial pressures of the combustible gases and oxygen and slowing the reaction rate.
- inert gases e.g. carbon dioxide and/or water
- the flame retardant used in the flame-retardant polymer compositions disclosed herein work by endothermic degradation and/or dilution of the gas phase.
- the flame retardant may, for example, be a particulate mineral flame retardant, an organohalogen and/or a phosphorous and/or nitrogen-containing compound.
- the particulate mineral flame retardant may, for example, be aluminium hydroxide (ATH - AI(OH) 3 ), magnesium hydroxide (MDH - Mg(OH) 2 ), a combination of huntite and hydromagnesite, a particulate mineral hydrate, red phosphorous, a borate, or a combination of one or more thereof.
- the particulate mineral flame retardant is aluminium hydroxide, magnesium hydroxide or a combination of huntite and hydromagnesite.
- the present invention may tend to be discussed in terms of aluminium hydroxide or magnesium hydroxide. However, the present invention should not be construed as being limited to such embodiment.
- the aluminium hydroxide may, for example, be gibbsite, bayerite, nordstrandite, doyleite or a combination of one or more thereof.
- the magnesium hydroxide may, for example, be brucite, chlorite or a combination of one or more thereof.
- the particulate mineral flame retardant may, for example, be coated with surface treatment agent such as a fatty acid (e.g. stearic acid), fatty acid ester (e.g. stearate) or silane. This may, for example, assist in compounding with the polymer matrix.
- the organohalogen compound may, for example, be an organochloride (e.g. chlorendic acid derivatives, chlorinated paraffin), an organobromide (e.g.
- decabromodiphenyl ether decabromodiphenyl ethane, brominated polystyrenes, brominated carbonate oligomers, brominated epoxy oligomers, tetrabromophthalic anhydride, tetrabromobisphenol A, hexabromocyclododecane), a halogenated organophosphate (e.g. tris(1 ,3-dichloro-2-propyl)phosphate, tetrakis(2- chlorethyl)dichloroisoentyldiphosphate), or a combination of one or more thereof.
- a halogenated organophosphate e.g. tris(1 ,3-dichloro-2-propyl)phosphate, tetrakis(2- chlorethyl)dichloroisoentyldiphosphate
- Organohalogen compounds may, for example, be used in combination with a synergist to enhance their efficacy.
- Synergists include antimony-containing compounds such as antimony trioxide, antimony pentoxide and sodium antimonite.
- the phosphorous and/or nitrogen-containing compound may, for example, be red phosphorous, a phosphate, a polyphosphate (e.g. melamine polyphosphate), an organophosphate (e.g. triphenyl phosphate (TPP), resorcinol bis(diphenylphosphate) (RDP), bisphenol A diphenyl phosphate (BADP), tricresyl phosphate (TCP)), a phosphonate (e.g. dimethyl methylphosphonate (DMMP), a phosphinate (e.g. aluminium diethyl phosphinate), a halogenated organophosphate (e.g.
- a phosphate e.g. melamine polyphosphate
- an organophosphate e.g. triphenyl phosphate (TPP), resorcinol bis(diphenylphosphate) (RDP), bisphenol A diphenyl phosphate (BADP), tricresyl
- the flame retardant may, for example, be present in the flame-retardant polymer composition in an amount of at least about 50 % based on the total weight of filler in the flame-retardant polymer composition. In other words, at least about 50 wt% of the filler (non-polymer) present in the flame-retardant polymer composition is the flame retardant.
- the flame retardant may be present in the flame-retardant polymer composition in an amount of at least about 52 wt% or at least about 54 wt% or at least about 55 wt% or at least about 57 wt% or at least about 59 wt% or at least about 60 wt% based on the total weight of filler in the flame-retardant polymer composition.
- the flame retardant may be present in the flame-retardant polymer composition in an amount up to about 70 wt% or up to about 69 wt% or up to about 68 wt% or up to about 67 wt% or up to about 66 wt% or up to about 65 wt% or up to about 64 wt% or up to about 63 wt% or up to about 62 wt% or up to about 61 wt% or up to about 60 wt% based on the total weight of filler in the flame-retardant polymer composition.
- the flame retardant may, for example, be present in the flame-retardant polymer composition in an amount of at least about 15 wt% based on the total weight of the flame-retardant polymer composition.
- the flame retardant may be present in the flame-retardant polymer composition in an amount of at least about 20 wt% or at least about 25 wt% or at least about 30 wt% or at least about 32 wt% or at least about 34 wt% or at least about 35 wt% or at least about 36 wt% or at least about 38 wt% or at least about 40 wt% or at least about 42 wt% or at least about 44 wt% or at least about 45 wt% based on the total weight of the flame-retardant polymer composition.
- the flame retardant may be present in the flame-retardant polymer composition in an amount up to about 60 wt% or up to about 58 wt% or up to about 56 wt% or up to about 55 wt% or up to about 54 wt% or up to about 52 wt% or up to about 50 wt% based on the total weight of the flame-retardant polymer composition.
- high aspect ratio particulate mineral refers to a mineral having particles that are acicular or lamellar. Lamellar particles generally have a small, flat and flaky or platy appearance. Acicular particles generally have a long, thin fibre or needle-like appearance.
- the high aspect ratio particulate mineral may, for example, be selected from talc, mica, wollastonite, halloysite and combinations of one or more thereof.
- a particulate talc mineral refers to lamellar particulate material made of hydrated magnesium silicate having the chemical formula H2Mg3(SiC>3)4 or Mg3Si40io(OH)2, or the mineral chlorite (hydrated magnesium aluminium silicate), a combination thereof, or a mineral substance derived therefrom and having similar properties.
- the particulate talc mineral may, for example, be obtained from a natural source by grinding.
- the particulate talc mineral may be obtained by or obtainable by delamination of talc suspended in a liquid.
- Natural talc particulate is typically obtained by crushing and then grinding a mineral source of talc, which may be followed by a particle size classification step, in order to obtain a product having a desired particle size distribution.
- the particulate solid material may be ground autogenously, i.e. by attrition between the particles of the solid material themselves, or, alternatively, in the presence of a particulate grinding medium comprising particles of a different material from the talc particulate to be ground. These processes may be carried out with or without the presence of a dispersant and biocides, which may be added at any stage of the process.
- the talc particulate is obtained and/or obtainable by a process according to that described in US-A-6348536, the entire contents of which are hereby incorporated by reference.
- the talc particulate may be prepared by a process comprising:
- the starting talc is typically chosen having an initial particle size which is greater than the desired particle size.
- the starting talc is suspended in water in the presence of a dispersing agent such that the weight of dry matter based on the total weight of the suspension is from about 10 % to about 60 %.
- the suspension is typically homogenous.
- the grinding operation during delamination is, in certain embodiments, carried out as to obtain a dsoiaser of from about 10 ⁇ to about 50 ⁇ .
- the selection step may comprise hydrodynamic selection, which may be carried out in a turbine selector or in a hydrocyclone or in a centrifuge with an endless extraction screw.
- the suspension is advantageously dried in such a way as to reach a residual liquid level below 1 %.
- the talc particulate is prepared by a process comprising:
- the inorganic particulate for example, talc particulate is not chemically treated during processing to obtain the desired particle size and lamellarity.
- a particulate wollastonite mineral refers to a calcium inosilicate mineral (CaSiC ) that may contain small amounts of iron, magnesium and/or manganese substituting for calcium.
- Wollastonite contains chains of [Si0 4 ] tetrahedral sharing common vertices, running parallel to the b-axis. The chain motif repeats after three tetrahedral. Wollastonite crystals are generally acicular in shape.
- a particulate halloysite mineral refers to a lamellar or acicular monoclinic aluminosilicate clay mineral with the empirical formula Al2Si20s(OH) 4 . Halloysite can be hydrated or unhydrated.
- the halloysite may, for example, have a moisture content equal to or less than about 5 wt% or equal to or less than about 4 wt% or equal to or less than about 3 wt% based on the total weight of the halloysite mineral.
- a particulate mineral e.g. particulate mineral flame retardant, high aspect ratio particulate mineral, intumescent particulate mineral
- talc may occur in association with other minerals such as dolomite.
- the particulate minerals used in the invention will each contain less than 5% by weight, for example less than 2 wt%, for example less than 1 % by weight of other minerals.
- the particulate minerals e.g. particulate mineral flame retardant, high aspect ratio particulate mineral and/or intumescent particulate mineral
- the particulate mineral is subjected to at least one physical modification process.
- the particulate minerals are each independently subjected to at least one chemical modification process.
- appropriate chemical modification processes include but are not limited to, silanization and calcination.
- the particulate talc material may, for example, be surface treated or surface untreated.
- the surface treatment may, for example, serve to modify a property of the talc particulate and/or the liquid composition into which it is incorporated.
- the surface treatment is present in an amount up to about 5 wt. %, based on the total weight of particulate mineral, for example, from about 0.001 wt. % to about 5 wt. %, or from about 0.01 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 2 wt. %, or from about 0.5 wt. % to about 1 .5 wt. %, based on the total weight of particulate mineral.
- the particulate mineral is not surface treated.
- the high aspect ratio particulate mineral may, for example, have a moisture content equal to or less than about 5 % based on the total weight of the high aspect ratio particulate mineral.
- the high aspect ratio particulate mineral e.g. halloysite
- the high aspect ratio particulate mineral may have a moisture content of at least about 0.5 wt% or at least about 1 wt% based on the total weight of the high aspect ratio particulate mineral.
- the high aspect ratio particulate mineral may, for example, have an aspect ratio ranging from about 2 to about 150.
- the high aspect ratio particulate mineral may have an aspect ratio ranging from about 2 to about 145 or from about 2 to about 140 or from about 2 to about 135 or from about 2 to about 130 or from about 2 to about 125 or from about 2 to about 120 or from about 2 to about 1 15 or from about 2 to about 1 10 or from about 2 to about 105 or from about 2 to about 100.
- the high aspect ratio particulate mineral may have an aspect ratio ranging from about 3 to about 95 or from about 4 to about 90 or from about 5 to about 85 or from about 6 to about 80 or from about 7 to about 75 or from about 8 to about 70 or from about 9 to about 65 or from about 10 to about 60.
- the expression "aspect ratio” means the diameter of the circle of area equivalent to that of a face of the particle divided by the mean thickness of that particle. Aspect ratio may be determined using electron microscopy methods. For example, for a given particle, for a superimposed circle having an area equivalent to that of the face of the particle, where the diameter of that circle is d, the thickness of the particle is t, the aspect ratio of the particle is d divided by t.
- the aspect ratio for platy minerals such as talc and mica may also, for example, be calculated by particle size analysis using the Parslow/Jennings or Pabst Equation.
- the high aspect ratio particulate mineral may, for example, have a dso (sedigraph) ranging from about 0.5 pm to about 20 pm.
- the high aspect ratio particulate mineral may have a dso (sedigraph) ranging from about 1 pm to about 20 m or from about 2 pm to about 19 pm or from about 3 pm to about 18 pm or from about 4 pm to about 17 pm or from about 5 pm to about 16 pm or from about 6 pm to about 15 pm or from about 7 pm to about 14 pm or from about 8 pm to about 13 pm or from about 9 pm to about 12 pm or from about 10 pm to about 1 1 pm.
- the high aspect ratio particulate mineral may, for example, have a d-io (sedigraph) ranging from about 0.05 pm to about 2 pm.
- the high aspect ratio particulate mineral may have a d-io (sedigraph) ranging from about 0.1 pm to about 1 .9 pm or from about 0.2 pm to about 1.8 pm or from about 0.3 pm to about 1 .7 pm or from about 0.4 pm to about 1 .6 pm or from about 0.5 pm to about 1 .5 pm or from about 0.6 pm to about 1 .4 pm or from about 0.7 pm to about 1 .3 pm or from about 0.8 pm to about 1 .2 pm or from about 0.9 pm to about 1 .1 pm.
- the high aspect ratio particulate mineral may, for example, have a dgo (sedigraph) ranging from about 3 pm to about 50 pm.
- the high aspect ratio particulate mineral may have a dgo (sedigraph) ranging from about 4 pm to about 45 pm or from about 5 pm to about 40 pm or from about 6 pm to about 39 pm or from about 7 pm to about 38 pm or form about 8 pm to about 37 pm or from about 9 pm to about 36 pm or from about 10 pm to about 35 pm or from about 1 1 pm to about 34 pm or from about 12 pm to about 33 pm or from about 13 pm to about 32 pm or from about 14 pm to about 31 pm or from about 15 pm to about 30 pm or from about 16 pm to about 29 pm or from about 17 pm to about 28 pm or from about 18 pm to about 27 pm or from about 19 pm to about 26 pm or from about 20 pm to about 25 pm.
- the high aspect ratio particulate mineral may, for example, have a dm (sedigraph) ranging from about 3 pm to about 60 pm.
- the high aspect ratio particulate mineral may have a die (sedigraph) ranging from about 4 pm to about 55 pm or from about 5 pm to about 50 pm or from about 5 pm to about 45 pm or from about 5 pm to about 40 pm or from about 6 pm to about 39 pm or from about 7 pm to about 38 pm or form about 8 pm to about 37 pm or from about 9 pm to about 36 pm or from about 10 pm to about 35 pm or from about 1 1 pm to about 34 pm or from about 12 pm to about 33 pm or from about 13 pm to about 32 pm or from about 14 pm to about 31 pm or from about 15 pm to about 30 pm or from about 16 pm to about 29 pm or from about 17 pm to about 28 pm or from about 1 8 pm to about 27 pm or from about 19 pm to about 26 pm or from about 20 pm to about 25 pm.
- the high aspect ratio particulate mineral may, for example, have a dso (laser) ranging from about 5 pm to about 40 pm.
- the high aspect ratio particulate mineral may have a dso (laser) ranging from about 6 pm to about 39 pm or from about 7 pm to about 38 pm or from about 8 pm to about 37 pm or from about 9 pm to about 36 pm or from about 10 pm to about 35 pm or from about 1 1 pm to about 34 pm or from about 12 pm to about 33 pm or from about 13 pm to about 32 pm or from about 14 pm to about 31 pm or from about 15 pm to about 30 pm or from about 16 pm to about 29 pm or from about 17 pm to about 28 pm or from about 18 pm to about 27 pm or from about
- the high aspect ratio particulate mineral may, for example, have a dio (laser) ranging from about 2 pm to about 10 pm.
- the high aspect ratio particulate mineral may have a dio (laser) ranging from about 3 pm to about 9 pm or from about 4 pm to about 8 pm or from about 5 pm to about 7 pm or from about 6 pm to about 7 pm.
- the high aspect ratio particulate mineral may, for example, have a dgo (laser) ranging from about 20 pm to about 80 pm.
- the high aspect ratio particulate mineral may have a dgo (laser) ranging from about 20 pm to about 75 pm or from about
- the high aspect ratio particulate mineral may, for example, have a dgs (laser) ranging from about 20 pm to about 100 pm.
- the high aspect ratio particulate mineral may have a dgs (laser) ranging from about 20 pm to about 95 pm or from about 20 pm to about 90 pm or from about 20 pm to about 85 pm or from about 20 pm to about 80 pm or from about 25 pm to about 75 pm or from about 30 pm to about 70 pm or from about 35 pm to about 65 pm or from about 40 pm to about 60 pm or from about 45 pm to about 55 pm or from about 50 pm to about 55 pm.
- the high aspect ratio particulate mineral may, for example, have a lamellarity index equal to or greater than about 2.8.
- the high aspect ratio particulate mineral e.g. talc
- the high aspect ratio particulate mineral may, for example, have a lamellarity index equal to or less than about 20.
- the high aspect ratio particulate mineral e.g. talc
- the high aspect ratio particulate mineral is talc having a dio (sedigraph) ranging from about 0.2 ⁇ to about 0.8 ⁇ and a dso (sedigraph) ranging from about 2 ⁇ to about 3.5 ⁇ .
- the high aspect ratio particulate mineral (talc) further has a dgs (sedigraph) ranging from about 5 ⁇ to about 25 ⁇ .
- the high aspect ratio particulate mineral (talc) further has a dg5 (sedigraph) ranging from about 5 ⁇ to about 15 ⁇ and a lamellarity index ranging from about 3 to about 4.
- the high aspect ratio particulate mineral (talc) further has a dgs (sedigraph) ranging from about 15 ⁇ to about 25 ⁇ and a lamellarity index ranging from about 5 to about 9.
- the high aspect ratio particulate mineral is talc having a dio (laser) ranging from about 2 ⁇ to about 8 ⁇ and a dso (laser) ranging from about 8 ⁇ to about 25 ⁇ .
- the high aspect ratio particulate mineral (talc) further has a dgs (laser) ranging from about 25 ⁇ to about 65 ⁇ .
- the high aspect ratio particulate mineral (talc) has a dso (laser) ranging from about 8 ⁇ to about 15 ⁇ and a dgs (laser) ranging from about 20 ⁇ to about 30. In certain embodiments, the high aspect ratio particulate mineral (talc) has a dso (laser) ranging from about 8 ⁇ to about 15 ⁇ and a dgs (laser) ranging from about 20 ⁇ to about 30 and a lamellarity index ranging from about 3 to about 5.
- the high aspect ratio particulate mineral (talc) has a dso (laser) ranging from about 8 ⁇ to about 15 ⁇ and a dgs (laser) ranging from about 25 ⁇ to about 35 ⁇ and/or a lamellarity index ranging from about 3 to about 4.
- the high aspect ratio particulate mineral (talc) has a dso (laser) ranging from about 15 ⁇ to about 30 ⁇ (e.g. from about 15 ⁇ to about 25 ⁇ ) and a dgs (laser) ranging from about 50 ⁇ to about 70 ⁇ (e.g. from about 55 ⁇ to about 65 ⁇ ) and/or a lamellarity index ranging from about 5 to about 9.
- Lamellarity index characterizes the shape and flatness of particles (large dimension/thickness).
- the term "lamellarity index" is defined by the following ratio: dsOlaser— dsOsedi
- dsOsedi in which "dsoiaser” is the value of the mean particle size (dso) obtained using a laser particle size analyser as described herein and "dsosedi” is the value of the median diameter obtained by sedimentation using a sedigraph (standard ISO 13317-3), as described herein.
- dsoiaser is the value of the mean particle size (dso) obtained using a laser particle size analyser as described herein
- dsosedi is the value of the median diameter obtained by sedimentation using a sedigraph (standard ISO 13317-3), as described herein.
- G. Baudet and J. P. Rona, Ind. Min. Mines et Carr. Les techn. June, July 1990, pp 55-61 which shows that this index is correlated to the mean ratio of the largest dimension of the particle to its smallest dimension.
- particle size properties referred to herein for the talc particulate materials are as measured in a well-known manner by sedimentation of the particulate material in a fully dispersed condition in an aqueous medium using a Sedigraph 5100 machine as supplied by Micromeritics Instruments Corporation, Norcross, Georgia, USA (www.micromeritics.com), referred to herein as a "Micromeritics Sedigraph 5100 unit", and based on application of Stokes' Law.
- Such a machine provides measurements and a plot of the cumulative percentage by weight of particles having a size, referred to in the art as the 'equivalent spherical diameter' (e.s.d), less than given e.s.d values.
- the mean particle size dsosedi is the value determined in this way of the particle e.s.d at which there are 50% by weight of the particles which have an equivalent spherical diameter less than that dso value.
- the d95sedi value is the value at which 95% by weight of the particles have an esd less than that d95sedi value.
- Particle size properties may be determined in accordance with ISO 13317-3, or any method equivalent thereto.
- the particle size ranges measured by sedigraph relate to the lamellar minerals.
- the particle size ranges measured by sedigraph relate to talc.
- particle size properties referred to herein for the particulate talc materials are measured by wet Malvern laser scattering (standard ISO 13320-1 ).
- the size of particles in powders, suspensions and emulsions may be measured using the diffraction of a laser beam, based on the application of Mie theory.
- a Malvern Mastersizer S as supplied by Malvern instruments
- the mean particle size dso is the value determined in this way of the particle e.s.d. at which there are 50% by weight of the particles which have an equivalent spherical diameter less than that dso value.
- the measurement of particle size using laser light scattering is not an equivalent method to the sedimentation method referred to above.
- the particle size ranges measured by the laser technique refer to acicular minerals.
- the particle size ranges measured by laser relate to wollastonite and/or halloysite.
- dso (sedigraph) and dso (laser) refer to the dso values measured respectively, according to the sedigraph or laser techniques described above.
- the high aspect ratio particulate mineral may, for example, have a BET surface area equal to or greater than about 1 m 2 /g.
- the high aspect ratio particulate mineral e.g. talc
- the high aspect ratio particulate mineral has a BET surface area equal to or greater than about 10 m 2 /g or equal to or greater than about 1 1 m 2 /g or equal to or greater than about 12 m 2 /g or equal to or greater than about 13 m 2 /g or equal to or greater than about 14 m 2 /g or equal to or greater than about 15 m 2 /g.
- the high aspect ratio particulate mineral may, for example, have a BET surface area equal to or less than about 30 m 2 /g.
- the high aspect ratio particulate mineral e.g. talc
- the high aspect ratio particulate mineral (e.g. talc) may, for example, have a BET surface area ranging from about 1 m 2 /g to about 25 m 2 /g or from about 10 m 2 /g to about 25 m 2 /g or from about 10 m 2 /g to about 20 m 2 /g.
- the high aspect ratio particulate mineral is talc having a BET surface area ranging from about 10 m 2 /g to about 30 m 2 /g or from about 10 m 2 /g to about 25 m 2 /g or from about 10 m 2 /g to about 20 m 2 /g.
- the high aspect ratio particulate mineral is mica having a BET surface area ranging from about 5 m 2 /g to about 20 m 2 /g or from about 5 m 2 /g to about 15 m 2 /g or from about 5 m 2 /g to about 10 m 2 /g.
- the high aspect ratio particulate mineral is halloysite having a BET surface area ranging from about 10 m 2 /g to about 30 m 2 /g or from about 15 m 2 /g to about 25 m 2 /g or from about 18 m 2 /g to about 22 m 2 /g.
- the high aspect ratio particulate mineral is wollastonite having a BET surface area ranging from about 1 m 2 /g to about 10 m 2 /g or from about 1 m 2 /g to about 5 m 2 /g or from about 1 m 2 /g to about 3 m 2 /g.
- BET surface area refers to the area of the surface of the particles of the particulate talc material with respect to unit mass, determined according to the BET method by the quantity of nitrogen adsorbed on the surface of said particles so as to form a monomolecular layer completely covering said surface (measurement according to the BET method, AFNOR standard X1 1 -621 and 622 or ISO 9277). In certain embodiments, BET surface area is determined in accordance with ISO 9277 or any method equivalent thereto.
- the high aspect ratio particulate mineral is talc having a dso (sedigraph) ranging from about 1 ⁇ to about 8 ⁇ (e.g. from about 2 ⁇ to about 8 ⁇ ) and BET surface area of at least about 10 m 2 /g.
- the high aspect ratio particulate mineral is talc having a dso (sedigraph) ranging from about 8 ⁇ to about 15 ⁇ and a BET surface area of at least about 5 m 2 /g.
- the high aspect ratio particulate mineral is talc having a dso (sedigraph) ranging from about 1 ⁇ to about 8 ⁇ (e.g.
- the high aspect ratio particulate mineral is wollastonite having a dso (laser) ranging from about 4 ⁇ to about 10 ⁇ .
- the wollastonite further has a dgs (laser) ranging from about 30 ⁇ to about 40 ⁇ .
- the wollastonite further has a dio (laser) ranging from about 0.5 ⁇ to about 3 ⁇ .
- the wollastonite further has an aspect ratio ranging from about 4 to about 10.
- the wollastonite further has a dg5 (laser) ranging from about 30 ⁇ to about 40 ⁇ and a dio (laser) ranging from about 0.5 ⁇ to about 3 ⁇ and an aspect ratio ranging from about 4 to about 10.
- the high aspect ratio particulate mineral is mica having a dso (sedigraph) ranging from about 1 ⁇ to about 9 ⁇ or ranging from about 2 ⁇ to about 8 ⁇ or ranging from about 3 ⁇ to about 7 ⁇ .
- the mica further has a dgo (sedigraph) ranging from about 20 ⁇ to about 35 ⁇ .
- the mica further has a dio (sedigraph) ranging from about 0.05 ⁇ to about 2 ⁇ .
- the high aspect ratio particulate mineral may, for example, be present in the flame- retardant polymer composition in an amount of at least about 5 % based on the total weight of the flame-retardant polymer composition.
- the high aspect ratio particulate mineral may be present in the flame-retardant polymer composition in an amount of at least about 5.5 wt% or at least about 6 wt% or at least about 6.5 wt% or at least about 7 wt% or at least about 7.5 wt% or at least about 8 wt% or at least about 8.5 wt% or at least about 9 wt% or at least about 9.5 wt% or at least about 10 wt% or at least about 10.5 wt% or at least about 1 1 wt% or at least about 1 1.5 wt% or at least about 12 wt% based on the total weight of the flame-retardant polymer composition.
- the high aspect ratio particulate mineral may, for example, be present in the flame- retardant polymer composition in an amount up to about 25 % based on the total weight of the flame-retardant polymer composition.
- the high aspect ratio particulate mineral may be present in the flame-retardant polymer composition in an amount up to about 24 wt% or up to about 23 wt% or up to about 22 wt% or up to about 21 wt% or up to about 20 wt% or up to about 19 wt% or up to about 18 wt% or up to about 17 wt% or up to about 16 wt% or up to about 15 wt% based on the total weight of the flame-retardant polymer composition.
- the high aspect ratio particulate mineral may be present in the flame- retardant polymer composition in an amount ranging from about 5 wt% to about 25 wt% or from about 10 wt% to about 20 wt% or from about 12 wt% to about 18 wt% or from about 13 wt% to about 16 wt% based on the total weight of the flame-retardant polymer composition.
- the term "intumescent particulate mineral” refers to any mineral that can swell as a result of heat exposure, thus increasing its volume and decreasing its density. Intumescent particulate minerals generally produce a char upon combustion which can act as a thermal insulation barrier between the burning and unburned materials.
- the intumescent particulate mineral may, for example, be selected from perlite (e.g. unexpanded perlite), graphite, sodium silicate, ammonium polyphosphate and combinations of one or more thereof.
- perlite e.g. unexpanded perlite
- graphite e.g. unexpanded perlite
- sodium silicate e.g. sodium silicate
- ammonium polyphosphate e.g., sodium silicate, ammonium polyphosphate and combinations of one or more thereof.
- the present invention may tend to be discussed in terms of perlite or unexpanded perlite. However, the invention should not be construed as being limited to such embodiments.
- Perlite is a hydrated natural glass that may contain, for example, about 72 to about 75% Si0 2 , about 12 to about 14% Al 2 0 3 , about 0.5 to about 2% Fe 2 0 3 , about 3 to about 5% Na 2 0, about 4 to about 5% K 2 0, about 0.4 to about 1.5% CaO (by weight), and small amounts of other metallic elements.
- Perlite may be distinguished from other natural glasses by a higher content (such as about 2 to about 5% by weight) of chemically-bonded water, the presence of a vitreous, pearly luster, and characteristic concentric or arcuate onion skin-like (i.e., perlitic) fractures. Perlite may be expanded or non-expanded.
- Perlite products may be prepared by milling and thermal expansion, and may possess unique physical properties such as high porosity, low bulk density, and chemical inertness. Average particle size for the milled expanded perlite ranges from 5 to 200 microns, pore volume ranges from 2 to 10 L/mg with median pore size from 5 to 20 microns. Prior to processing, perlite may be gray to green in color with abundant spherical cracks that cause it to break into small pearl-like masses.
- the intumescent mineral may, for example, have a dso (laser) ranging from about 1 ⁇ to about 20 ⁇ .
- the intumescent mineral may have a dso (laser) ranging from about 2 ⁇ to about 20 ⁇ or from about 3 ⁇ to about 19 ⁇ or from about 4 ⁇ to about 18 ⁇ or from about 5 ⁇ to about 17 ⁇ or from about 6 ⁇ to about 16 ⁇ or from about 7 ⁇ to about 15 ⁇ or from about 8 ⁇ to about 14 ⁇ or from about 9 ⁇ to about 13 ⁇ or from about 10 ⁇ to about 12 ⁇ .
- the intumescent mineral may, for example, have a dio (laser) ranging from about 0.1 ⁇ to about 3 ⁇ .
- the intumescent mineral may have a dio (laser) ranging from about 0.2 ⁇ to about 2.5 ⁇ or from about 0.5 ⁇ to about 2 ⁇ or from about 1 ⁇ to about 2 ⁇ .
- the intumescent mineral may, for example, have a dgo (laser) ranging from about 5 ⁇ to about 50 ⁇ .
- the intumescent mineral may have a dgo (laser) ranging from about 6 ⁇ to about 50 ⁇ or from about 7 ⁇ to about 50 ⁇ or from about 8 ⁇ to about 50 ⁇ or from about 9 ⁇ to about 50 ⁇ or from about 10 ⁇ to about 50 ⁇ or from about 12 ⁇ to about 48 ⁇ or from about 14 ⁇ to about 46 ⁇ or from about 15 ⁇ to about 45 ⁇ or from about 16 ⁇ to about 44 ⁇ or from about 18 ⁇ to about 42 ⁇ or from about 20 ⁇ to about 40 ⁇ or from about 22 ⁇ to about 38 ⁇ or from about 24 ⁇ to about 36 ⁇ or from about 25 ⁇ to about 35 ⁇ or from about 26 ⁇ to about 34 ⁇ or from about 28 ⁇ to about 32 ⁇ .
- the intumescent particulate mineral may, for example, be present in the flame- retardant polymer composition in an amount of at least about 5 % based on the total weight of the flame-retardant polymer composition.
- the intumescent particulate mineral may be present in the flame-retardant polymer composition in an amount of at least about 6 wt% or at least about 7 wt% or at least about 8 wt% or at least about 9 wt% or at least about 10 wt% based on the total weight of the flame- retardant polymer composition.
- the intumescent particulate mineral may, for example, be present in the flame- retardant polymer composition in an amount up to about 15 % based on the total weight of the flame-retardant polymer composition.
- the intumescent mineral may be present in the flame-retardant polymer composition in an amount up to about 14 wt% or up to about 13 wt% or up to about 12 wt% or up to about 1 1 wt% or up to about 10 wt%.
- the flame-retardant polymer composition further comprises a siliceous mineral.
- siliceous mineral refers to any mineral comprising greater than 50 wt% silica (S1O2).
- the siliceous mineral may, for example, be selected from fumed silica, fused silica (fused quartz), quartz, tridymite, cristobalite, coesite, stishovite, zeolite, diatomaceous earth (DE), perlite and combinations thereof.
- fumed silica fused silica (fused quartz), quartz, tridymite, cristobalite, coesite, stishovite, zeolite, diatomaceous earth (DE), perlite and combinations thereof.
- the present invention may tend to be discussed in terms of fumed silica, fused silica or diatomaceous earth. However, the invention should not be construed as being limited to such embodiments.
- the siliceous particulate mineral may, for example, have a dso (laser) ranging from about 1 ⁇ to about 30 ⁇ .
- the siliceous mineral may have a dso (laser) ranging from about 1 ⁇ to about 28 ⁇ or from about 1 ⁇ to about 26 ⁇ or from about 1 ⁇ to about 25 ⁇ or from about 1 ⁇ to about 24 ⁇ or from about 1 ⁇ to about 22 m or from about 1 ⁇ to about 20 ⁇ or from about 1 ⁇ to about 18 ⁇ or from about 1 ⁇ to about 16 ⁇ or from about 1 ⁇ to about 15 ⁇ .
- the siliceous mineral may have a dso (laser) ranging from about 2 ⁇ to about 20 ⁇ or from about 3 ⁇ to about 19 ⁇ or from about 4 ⁇ to about 18 ⁇ or from about 5 ⁇ to about 17 ⁇ .
- the siliceous particulate mineral may, for example, have a dio (laser) ranging from about 0.1 ⁇ to about 5 ⁇ .
- the siliceous mineral may have a dio (laser) ranging from about 0.2 ⁇ to about 4 ⁇ or from about 0.3 ⁇ to about 3 ⁇ or from about 0.4 ⁇ to about 2.5 ⁇ or from about 0.5 ⁇ to about 2 ⁇ or from about 1 ⁇ to about 2.5 ⁇ or from about 1 ⁇ to about 2 ⁇ .
- the siliceous particulate mineral may, for example, have a dgo (laser) ranging from about 5 ⁇ to about 50 ⁇ .
- the siliceous mineral may have a dgo (laser) ranging from about 6 ⁇ to about 48 ⁇ or from about 8 ⁇ to about 46 ⁇ or from about 9 ⁇ to about 45 ⁇ or from about 10 ⁇ to about 44 ⁇ or from about 1 1 ⁇ to about 42 ⁇ or from about 12 ⁇ to about 40 ⁇ .
- a dgo laser
- the siliceous particulate mineral may, for example, be present in the flame-retardant polymer composition in an amount of at least about 0.5 wt% based on the total weight of the flame-retardant polymer composition.
- the siliceous mineral may be present in the flame-retardant polymer composition in an amount of at least about 1 wt% or at least about 1.5 wt% or at least about 2 wt% or at least about 2.5 wt% based on the total weight of the flame-retardant polymer composition.
- the siliceous particulate mineral may, for example, be present in the flame-retardant polymer composition in an amount up to about 5 % based on the total weight of the flame-retardant polymer composition.
- the siliceous mineral may be present in the flame-retardant polymer composition in an amount up to about 4.5 wt% or up to about 4 wt% or up to about 3.5 wt% or up to about 3 wt% or up to about 2.5 wt% based on the total weight of the flame-retardant polymer composition.
- the flame-retardant polymer composition may, for example, comprise further additives.
- the flame-retardant polymer composition may further comprise one or more of coupling agents (e.g. maleic anhydride grafted polyolefins), compatibilizers (e.g.
- maleic anhydride grafted polyolefins opacifying agents, pigments, colorants, slip agents (for example Erucamide), antioxidants, anti-fog agents, anti-static agents, anti- block agents, moisture barrier additives, gas barrier additives, dispersants, hydrocarbon waxes, stabilizers, co-stabilizers, lubricants, agents to improve tenacity, agents to improve heat-and-form stability, agents to improve processing performance, process aids (for example Polybatch® AMF-705), mould release agents (e.g.
- fatty acids zinc, calcium, magnesium, lithium salts of fatty acids, organic phosphate esters, stearic acid, zinc stearate, calcium stearate, magnesium stearate, lithium stearate, calcium oleate, zinc palmiate), antioxidants and plasticizers.
- each of the further additives may independently be present in the flame-retardant polymer composition in an amount ranging from about 0 % to about 2 % based on the total weight of the flame-retardant polymer composition.
- each of the further additives may be present in the flame-retardant polymer composition in an amount ranging from about 0 % to about 1 .5 % or from about 0 % to about 1 % or from about 0 % to about 0.5 %.
- the flame-retardant polymer composition may, for example, comprise no more than about 10 wt% or no more than about 5 wt% or no more than about 4 wt% or no more than about 3 wt% or no more than about 2 wt% of further additives based on the total weight of the flame-retardant polymer composition.
- Each of the components of the flame-retardant polymer composition disclosed herein may be present in any amount within the ranges specified herein provided that the total wt% of the flame-retardant polymer composition is 100 wt%.
- the flame-retardant polymer composition may, for example, be a class C or above (e.g. class C, B2 ca , B1 ca ) polymer composition when measured by the Construction Products Regulation (CPR). Flame spread and heat release are measured by EN50399 and flame propagation is measured by EN60332-1 -2.
- CPR Construction Products Regulation
- Class B1 ca materials have a flame spread (test EN 50399) equal to or less than 1.75 m, a total heat release (THR1200 equal to or less than 10 MJ, a peak of heat release rate equal to or less than 20 kW, a fire growth rate index equal to or less than 120 W/s and a flame spread (test EN60332-1 -2) equal to or less than 425 mm.
- Test EN 50399 is carried out using a 30 kW burner special assembly.
- Class B2 ca materials have a flame spread (test EN 50399) equal to or less than 1 .5 m, a total heat release (THR1200 equal to or less than 15 MJ, a peak of heat release rate equal to or less than 30 kW, a fire growth rate index equal to or less than 150 W/s and a flame spread (test EN60332-1 -2) equal to or less than 425 mm.
- Test EN 50399 is carried out using a 20.5 kW burner.
- Class C materials have a flame spread (test EN 50399) equal to or less than 2.0 m, a total heat release (THR1200 equal to or less than 30 MJ, a peak of heat release rate equal to or less than 60 kW, a fire growth rate index equal to or less than 300 W/s and a flame spread (test EN60332-1 -2) equal to or less than 425 mm.
- Test EN 50399 is carried out using a 20.5 kW burner.
- the flame-retardant polymer composition may be an s2 or s1 product.
- the flame-retardant polymer composition may be a d1 or dO product.
- the flame-retardant polymer composition may be an a2 or a1 product.
- the flame-retardant polymer composition may, for example, have a higher class ranking when measured by the Construction Products Regulation in comparison to a comparative composition that is identical except that it comprises an additional amount of the flame retardant (e.g. ATH or MDH) in place of the high aspect ratio particulate mineral, intumescent mineral and optional siliceous mineral.
- the flame- retardant polymer compositions provide improved flame-retardancy properties by replacing some of the flame retardant (e.g. ATH or MDH) by a high aspect ratio particulate mineral, intumescent mineral and optional siliceous mineral.
- the article may, for example, be a cable covered with a flame-retardant polymer composition as disclosed herein.
- the thickness of the flame-retardant polymer composition covering the cable may, for example, be equal to or less than about 1 mm.
- the thickness of the flame-retardant polymer composition may be equal to or less than about 0.9 mm or equal to or less than about 0.8 mm or equal to or less than about 0.7 mm or equal to or less than about 0.6 mm.
- the thickness of the flame- retardant polymer composition covering the cable may, for example, be at least about 0.1 mm or at least about 0.2 mm.
- the article may, for example, an elastomeric seal.
- the article may, for example, be an elastomeric bearing.
- the article may, for example, be a flexible sheet, for example for waterproofing and/or thermal insulation.
- the article may, for example, be an electrical appliance.
- the flame-retardant polymer compositions described herein may, for example, be made by compounding the polymer with the flame retardant, high aspect ratio particulate mineral, intumescent particulate mineral and any optional additives.
- Compounding per se is a technique which is well known to persons skilled in the art of polymer processing and manufacture and consists of preparing plastic formulations by mixing and/or blending polymers and optional additives in a molten state. It is understood in the art that compounding is distinct from blending or mixing processes conducted at temperatures below that at which the constituents become molten.
- Compounding may, for example, be used to form a masterbatch composition.
- Compounding may, for example, involve adding a masterbatch composition to a polymer to form a further polymer composition.
- the flame-retardant polymer compositions described herein may, for example, be extruded.
- compounding may be carried out using a screw, e.g. a twin screw, compounder, for example, a Baker Perkins 25 mm twin screw compounder.
- compounding may be carried out using a multi roll mill, for example a two-roll mill.
- compounding may be carried out using a co-kneader or internal mixer.
- the methods disclosed herein may, for example, include compression moulding or injection moulding.
- the polymer and/or flame retardant and/or high aspect ratio particulate mineral and/or intumescent minerals and/or optional additives may be premixed and fed from a single hopper.
- the resulting melt may, for example, be cooled, for example in a water bath, and then pelletized.
- the resulting melt may be calendared to form a sheet or film.
- the flame-retardant polymer compositions described herein may, for example, be shaped into a desired form or article. Shaping of the flame-retardant polymer compositions may, for example, involve heating the composition to soften it.
- the polymer compositions described herein may, for example, be shaped by molding (e.g. compression molding, injection molding, stretch blow molding, injection blow molding, overmolding), extrusion, casting, or themoforming.
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Abstract
L'invention concerne une composition de polymère ignifuge comprenant un polymère, un retardateur de flamme, un minéral particulaire à rapport de forme élevé et un minéral particulaire intumescent, des articles comprenant ou fabriqués à partir de ladite composition de polymère ignifuge et un procédé de fabrication de ladite composition de polymère ignifuge.
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| CN110092975A (zh) * | 2019-04-03 | 2019-08-06 | 上海新益电力线路器材有限公司 | 绝缘料、聚乙烯基云母协同增强绝缘阻燃电缆及制备方法 |
| CN115551953A (zh) * | 2020-05-11 | 2022-12-30 | 伊梅斯切公司 | 滑石颗粒物 |
| US20220389196A1 (en) * | 2021-06-08 | 2022-12-08 | Konica Minolta, Inc. | Resin composition and production method of same |
| CN114395189A (zh) * | 2021-12-17 | 2022-04-26 | 金发科技股份有限公司 | 一种聚烯烃组合物及其制备方法和应用 |
| CN114395189B (zh) * | 2021-12-17 | 2023-09-26 | 金发科技股份有限公司 | 一种聚烯烃组合物及其制备方法和应用 |
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