CA2584154A1 - Flame retardant composites - Google Patents

Flame retardant composites Download PDF

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Publication number
CA2584154A1
CA2584154A1 CA002584154A CA2584154A CA2584154A1 CA 2584154 A1 CA2584154 A1 CA 2584154A1 CA 002584154 A CA002584154 A CA 002584154A CA 2584154 A CA2584154 A CA 2584154A CA 2584154 A1 CA2584154 A1 CA 2584154A1
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CA
Canada
Prior art keywords
composite
flame retardant
less
polymer
aspect ratio
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002584154A
Other languages
French (fr)
Other versions
CA2584154C (en
Inventor
Ralph Bauer
Doruk Yener
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Ceramics and Plastics Inc
Original Assignee
Saint-Gobain Ceramics & Plastics, Inc.
Ralph Bauer
Doruk Yener
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Application filed by Saint-Gobain Ceramics & Plastics, Inc., Ralph Bauer, Doruk Yener filed Critical Saint-Gobain Ceramics & Plastics, Inc.
Publication of CA2584154A1 publication Critical patent/CA2584154A1/en
Application granted granted Critical
Publication of CA2584154C publication Critical patent/CA2584154C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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    • 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
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F7/00—Compounds of aluminium
    • C01F7/02—Aluminium oxide; Aluminium hydroxide; Aluminates
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F7/00—Compounds of aluminium
    • C01F7/02—Aluminium oxide; Aluminium hydroxide; Aluminates
    • C01F7/44—Dehydration of aluminium oxide or hydroxide, i.e. all conversions of one form into another involving a loss of water
    • C01F7/447—Dehydration of aluminium oxide or hydroxide, i.e. all conversions of one form into another involving a loss of water by wet processes
    • C01F7/448—Dehydration of aluminium oxide or hydroxide, i.e. all conversions of one form into another involving a loss of water by wet processes using superatmospheric pressure, e.g. hydrothermal conversion of gibbsite into boehmite
    • 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
    • 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
    • C08K7/02—Fibres or whiskers
    • C08K7/04—Fibres or whiskers inorganic
    • C08K7/08—Oxygen-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K21/00—Fireproofing materials
    • C09K21/02—Inorganic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/10—Particle morphology extending in one dimension, e.g. needle-like
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/20—Particle morphology extending in two dimensions, e.g. plate-like
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/30—Particle morphology extending in three dimensions
    • C01P2004/45—Aggregated particles or particles with an intergrown morphology
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/60—Particles characterised by their size
    • C01P2004/62—Submicrometer sized, i.e. from 0.1-1 micrometer
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/12—Surface area
    • 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
    • C08K2201/00—Specific properties of additives
    • C08K2201/016—Additives defined by their aspect ratio

Abstract

A flame retardant polymer composite is disclosed. The composite includes a polymer base material and a flame retardant filler provided in the polymer base material, the flame retardant filler containing seeded boehmite particulate material having an aspect ratio of not less than 3:1.

Claims (41)

1. ~A flame retardant polymer composite, comprising:
a polymer base material; and a flame retardant fillet provided in the polymer base material, the flame retardant filler comprising seeded boehmite particulate material having an aspect ratio of not less than 3:1, wherein the composite has a flame retardancy of V-0 or V-1 according to UL94.
2. ~The composite of claim 1, wherein the composite has a flame retardancy of V-0.
3. ~The composite of claim 1, wherein the composite has said flame retardancy in cured form.
4. ~The composite of claim 3, wherein the composite is a polymer component.
5. ~A flame retardant polymer composite, comprising:
a polymer base material; and a flame retardant filler provided in the polymer base material, the flame retardant fillet comprising seeded boehmite particulate material having an aspect ratio of not less than 3:1, wherein the composite is in the form of a surface coating solution, the composite having said flame retardancy in coated form.
6. ~The composite of claim 1, wherein the polymer base material has a flame retardancy of V-2 or higher, the filler functioning to improve the flame retardancy to composite to V-1 or V-0 according to UL 94.
7. ~The composite of claim 1, wherein the polymer base material is selected from the group consisting of polyolefins, polyesters, fluoropolymers, polyamides, polyimides, polycarbonates, polymers containing styrene, epoxy resins, polyurethane, polyphenol, silicone, and combinations thereof.
8. ~The composite of claim 7, wherein the polymer base material is a non-chlorinated polymer and is a non-fluorinated polymer, and is selected from the group consisting of polyolefins, polyesters, polyamides, polyimides, polycarbonates, polymers containing styrene, epoxy resins, polyurethane, polyphenol, and combinations thereof.
9. ~The composite of claim 1, wherein the flame retardant filler further includes additional components.
10.~The composite of claim 9, wherein the additional components are selected from the group consisting of iron oxide and a vitrifying agent.
11. ~The composite of claim 10, wherein the vitrifying agent includes zinc borate.
12. ~The composite of claim 1, further comprising a thermally conductive filler.
13. ~The composite of claim 12, wherein the thermally conductive filler is selected from the group consisting of boron nitride and alumina.
14. ~The composite of claim 1, wherein the composite comprises about 0.5 to 50.0 wt% flame retardant filler.
15. ~The composite of claim 14, wherein the composite comprises about 2.0 to 30.0 wt% flame retardant filler.
16. ~The composite of claim 15, wherein the composite comprises about 2.0 to 15.0 wt% flame retardant filler.
17. ~The composite of claim 1, wherein the seeded boehmite particulate material has an aspect ratio of not less than 4:1.
18. ~The composite of claim 1, wherein the seeded boehmite particulate material has an aspect ratio of not less than 6:1.
19. ~The composite of claim 1, wherein the seeded boehmite particulate material has an aspect ratio of not less than 9:1.
20. ~A flame retardant polymer composite, comprising:
a polymer base material; and a flame retardant filler provided in the polymer base material, the flame retardant filler comprising seeded boehmite particulate material having an aspect ratio of not less than 3:1, wherein the seeded boehmite particulate material predominantly comprises platelet-shaped particles, having a secondary aspect ratio of not less than 3:1.
21. ~The composite of claim 20, wherein the secondary aspect ratio is not less than 6:1.
22. ~The composite of claim 21, wherein the secondary aspect ratio is not less than 10:1.
23. ~The composite of claim 1, wherein the seeded boehmite particulate material predominantly comprises needle-shaped particles.
24. ~The composite of claim 23, wherein the needle-shaped particles have a secondary aspect ratio of not greater than 3:1.
25. ~The composite of claim 24, wherein the secondary aspect ratio is not greater than 2:1.
26. ~The composite of claim 1, wherein the average particle size of the seeded boehmite particulate material is not greater than 1000 nm.
27. ~The composite of claim 26, wherein the average particle size is between about 100 and 1000nm.
28. ~The composite of claim 27, wherein the average particle size is not greater than 800 nm.
29. ~The composite of claim 28, wherein the average particle size is not greater than 600 nm.
30. ~The composite of claim 29, wherein the average particle size is not greater than 500 nm.
31. ~The composite of claim 30, wherein the average particle size is not greater than 400 nm.
32. ~The composite of claim 31, wherein the average particle size is not greater than 300 nm.
33. ~The composite of claim 1, wherein the boehmite particulate material has a specific surface area of not less than about 10 m2/g.
34. ~The composite of claim 33, wherein the specific surface area is not less than about 50 m2/g.
35. ~The composite of claim 34, wherein the specific surface area is not less than about 70 m2/g.
36. ~The composite of claim 35, wherein the specific surface area is not greater than about 400 m2/g.
37. ~A method of forming a flame retardant polymer composite, comprising:
providing a polymer base material; and combining a flame retardant filler with the polymer base material to form the flame retardant polymer composite, the flame retardant filler comprising seeded boehmite particulate material having an aspect ratio of not less than 3:1, wherein the composite has a flame retardancy of V-0 or V-1 according to UL94.
38. ~The method of claim 37, further including shape forming following combining, the flame retardant composite being a polymer component.
39. ~The method of claim 37, wherein the flame retardant composite is a surface coating solution.
40. ~The method of claim 37, wherein the composite has a flame retardancy of V-0.
41.~The method of claim 37, wherein the polymer base material has a flame retardancy of V-2 or higher, the filler functioning to improve the flame retardancy to composite to V-1 or V-0 according to UL 94.
CA2584154A 2004-10-29 2005-10-17 Flame retardant composites Expired - Fee Related CA2584154C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/978,286 2004-10-29
US10/978,286 US20050124745A1 (en) 2002-04-19 2004-10-29 Flame retardant composites
PCT/US2005/037410 WO2006049863A1 (en) 2004-10-29 2005-10-17 Flame retardant composites

Publications (2)

Publication Number Publication Date
CA2584154A1 true CA2584154A1 (en) 2006-05-11
CA2584154C CA2584154C (en) 2010-03-23

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA2584154A Expired - Fee Related CA2584154C (en) 2004-10-29 2005-10-17 Flame retardant composites

Country Status (17)

Country Link
US (2) US20050124745A1 (en)
EP (1) EP1805252B1 (en)
JP (2) JP2008518084A (en)
KR (1) KR100838231B1 (en)
CN (1) CN101048450B (en)
AU (1) AU2005301161B2 (en)
BR (1) BRPI0518199A (en)
CA (1) CA2584154C (en)
ES (1) ES2405602T3 (en)
IL (1) IL182794A (en)
MX (1) MX2007005173A (en)
NO (1) NO20072691L (en)
RU (1) RU2346017C1 (en)
TW (1) TWI330646B (en)
UA (1) UA85304C2 (en)
WO (1) WO2006049863A1 (en)
ZA (1) ZA200703449B (en)

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