U.S. patent application number 10/533579 was filed with the patent office on 2007-08-23 for fire resistant material.
This patent application is currently assigned to Commonwealth Scientific & Industrial Research Org. a Australian Corporation. Invention is credited to Matthew Allen Anglin, Stuart Arthur Bateman.
Application Number | 20070194289 10/533579 |
Document ID | / |
Family ID | 28795766 |
Filed Date | 2007-08-23 |
United States Patent
Application |
20070194289 |
Kind Code |
A1 |
Anglin; Matthew Allen ; et
al. |
August 23, 2007 |
Fire resistant material
Abstract
The present invention relates to inorganic-organic hybrids
(IOHs), methods for their preparation and their use as fire
resistant materials or components of fire resistant materials. More
specifically, the invention relates to polyamide fire resistant
formulations containing IOHs which have application in the
production of fire resistant articles or parts thereof for use in
the transportation, building, construction and electrical or
optical industries.
Inventors: |
Anglin; Matthew Allen;
(Seattle, WA) ; Bateman; Stuart Arthur; (Victoria,
AU) |
Correspondence
Address: |
LADAS & PARRY
5670 WILSHIRE BOULEVARD, SUITE 2100
LOS ANGELES
CA
90036-5679
US
|
Assignee: |
Commonwealth Scientific &
Industrial Research Org. a Australian Corporation
The Boeing Company a United States Of America
Corporation
|
Family ID: |
28795766 |
Appl. No.: |
10/533579 |
Filed: |
October 31, 2003 |
PCT Filed: |
October 31, 2003 |
PCT NO: |
PCT/AU03/01443 |
371 Date: |
February 6, 2007 |
Current U.S.
Class: |
252/601 ;
252/378R |
Current CPC
Class: |
C01B 33/44 20130101;
C09K 21/06 20130101 |
Class at
Publication: |
252/601 ;
252/378.00R |
International
Class: |
C09K 21/00 20060101
C09K021/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 31, 2002 |
AU |
2002952373 |
Claims
1. An inorganic-organic hybrid (IOH) which comprises: (i) an
expandable or swellable layered inorganic component; and (ii) an
organic component including at least one ionic organic component
and one or more neutral organic components which are intercalated
between and/or associated with the layer(s) of the inorganic
component, the ionic or neutral organic components being capable of
decomposing or subliming endothermically, and/or releasing
volatiles with low combustibility on decomposition and/or inducing
charring of organic species during thermal decomposition or
combustion.
2. An IOH according to claim 1, in which the inorganic component is
rendered positively or negatively charged due to isomorphic
substitution of elements within the layers.
3. An IOH according to claim 1, in which the inorganic component is
selected from a 1:1 layered silicate structure, a 2:1 layered
silicate structure, a double hydroxide of the general formula
Mg.sub.6Al.sub.3.4(OH).sub.18.8(CO.sub.3).sub.1.7.H.sub.2O and a
synthetically prepared layered material.
4. An IOH according to claim 1, in which the inorganic compound is
a naturally occurring or a synthetic analogue of a
phyllosilicate.
5. An IOH according to claim 4, in which the naturally occurring or
synthetic analogue of a phyllosilicate is a smectite clay.
6. An IOH according to claim 5, in which the smectite clay is
selected from montmorillonite, nontronite, beidellite,
volkonskoite, hectorite, bentonite, saponite, sauconite, magadiite,
kenyaite, laponite, vermiculite, synthetic micromica and synthetic
hectorite.
7. An IOH according to claim 5, in which the naturally occurring
phyllosilicate is selected from bentonite, montmorillonite and
hectorite.
8. An IOH according to claim 4, in which the phyllosilicate has a
platelet thickness less than about 5 nanometers and an aspect ratio
greater than about 10:1.
9. An IOH according to claim 8, in which the aspect ratio is
greater than about 50:1.
10. An IOH according to claim 8, in which the aspect ratio is
greater than about 100:1.
11. An IOH according to claim 1, in which the inorganic component
includes interlayer or exchangeable metal cations to balance the
charge.
12. An IOH according to claim 11, in which the metal cation is
selected from an alkali metal and alkali earth metal.
13. An IOH according to claim 12, in which the alkali or alkali
earth metal is selected from Na.sup.+, K.sup.+, Mg.sup.2+ and
Ca.sup.2+.
14. An IOH according to claim 11, in which the cation exchange
capacity of the inorganic component is less than about 400
milli-equivalents per 100 grams.
15. An IOH according to claim 11, in which the ionic organic
component is exchanged with the exchangeable metal ions of the
inorganic component.
16. An IOH according to claim 1, in which the ionic species
contains onium ion(s).
17. An IOH according to claim 16, in which the ionic species
containing onium ion(s) is an ammonium, phosphonium or sulfonium
derivative of an aliphatic, aromatic or aryl-aliphatic amine,
phosphine or sulfide.
18. An IOH according to claim 1, in which the ionic or neutral
organic component is a neutral or ionic derivative of a nitrogen
based molecule.
19. An IOH according to claim 18, in which the nitrogen based
molecule is a triazine based species.
20. An IOH according to claim 19, in which the triazine based
species is selected from melamine, triphenyl melamine, melam
(1,3,5-triazine-2,4,6-triamine-n-(4,6-diamino-1,3,5-triazine-yl)),
melem ((-2,5,8-triamino-1,3,4,6,7,9,9b-heptaazaphenalene)), melon
(poly{8-amino-1,3,4,6,7,9,9b-heptaazaphenalene-2,5diyl)imino}), bis
and triaziridinyltriazine, trimethylsilyltriazine, melamine
cyanurate, melamine phthalate, melamine phosphate, melamine
phosphite, melamine phthalimide, dimelamine phosphate,
phosphazines, low molecular weight polymers with triazine and
phosphazine repeat units and isocyanuric acid and salts or
derivatives thereof.
21. An IOH according to claim 20, in which isocyanuric acid and
salts or derivatives thereof are selected from isocyanuric acid,
cyanuric acid, triethyl cyanurate, melamine cyanurate,
trigylcidylcyanurate, triallyl isocyanurate, trichloroisocyanuric
acid, 1,3,5-tris(2-hydroxyethyl)triazine-2,4,6-trione,
hexamethylenentetramine.melam cyanurate, melem cyanurate and melon
cyanurate.
22. An IOH according to claim 18, in which the organic component is
a derivative of phosphoric acid or boric acid.
23. An IOH according to claim 22, in which the derivative of
phosphoric acid or boric acid is selected from ammonia
polyphosphate, melamine polyphosphate and melamine phosphate
ammonium borate.
24. An IOH according to claim 1, in which the ionic organic
component is used in combination with other ionic compounds which
are capable of improving compatibility and dispersion between the
inorganic and organic components.
25. An IOH according to claim 24, in which the other ionic compound
is an amphiphilic molecule that incorporates a hydrophilic ionic
group along with hydrophobic alkyl or aromatic moieties.
26. An IOH according to claim 1, which further comprises one or
more coupling reagents.
27. An IOH according to claim 26, in which the coupling reagent is
selected from an organically functionalised silane, zirconate and
titanate.
28. An IOH according to claim 27, in which the silane coupling
reagent is tri-alkoxy, acetoxy or halosilanes functionalised with
amino, epoxy, isocyanate, hydroxyl, thiol, mercapto and/or
methacryl reactive moieties or modified to incorporate functional
groups based on triazine derivatives, long chain alkyl, aromatic or
alkylaromatic moieties.
29. A method for the preparation of the IOH defined in claim 1,
which comprises mixing components (i) and (ii) or constituents
thereof in one or more steps.
30. A method according to claim 29, in which mixing is achieved
using melt, solution or powder processing.
31. A method according to claim 29, in which the mixing is achieved
using solution processing.
32. A method for using the IOH defined in claim 1 as a fire
resistant material.
33. A fire resistant formulation which comprises: (i) the IOH
defined in claim 1; and (ii) one or more flame retardants.
34. A formulation according to claim 33, in which the flame
retardant is selected from phosphorus derivatives, nitrogen
containing derivatives, molecules containing borate functional
groups, molecules containing two or more alcohol groups, molecules
which endothermically release non-combustible decomposition gases
and expandable graphite.
35. A formulation according to claim 34, in which the phosphorus
derivatives are selected from melamine phosphate, dimelamine
phosphate, melamine polyphosphate, ammonia phosphate, ammonia
polyphosphate, pentaerythritol phosphate, melamine phosphite and
triphenylphosphine.
36. A formulation according to claim 34, in which the nitrogen
containing derivatives are selected from melamine, melamine
cyanurate, melamine phthalate, melamine phthalimide, melam, melem,
melon, melam cyanurate, melem cyanurate, melon cyanurate,
hexamethylene tetraamine, imidazole, adenine, guanine, cytosine and
thymine.
37. A formulation according to claim 34, in which the molecules
containing borate functional groups are selected from ammonia
borate and zinc borate.
38. A formulation according to claim 34, in which the molecules
containing two or more alcohol groups are selected from
pentaerytliritol, polyethylene alcohol, polyglycols and
carbohydrates.
39. A formulation according to claim 34, in which the molecules
which endothermically release non-combustible decomposition gases
are selected from magnesium hydroxide and aluminum hydroxide.
40. A method for the preparation of the fire resistant formulation
defined in claim 33, which comprises mixing the following
components or constituents thereof in one or more steps: (i) an
expandable or swellable layered inorganic component; and (ii) an
organic component including at least one ionic organic component
and one or more neutral organic components which are intercalated
between and/or associated with the layer(s) of the inorganic
component, the ionic or neutral organic components being capable of
decomposing or subliming endothermically, and/or releasing
volatiles with low combustibility on decomposition and/or inducing
charring of organic species during thermal decomposition or
combustion.
41. A method according to claim 40, in which mixing is achieved
using melt, solution or powder processing.
42. A method according to claim 40, in which the mixing is achieved
using melt processing in a twin screw extruder or batch mixer; or
powder processing using a high shear powder mixer or milling
procedures.
43. A polyamide fire resistant formulation which comprises either:
(A) (i) the IOH defined in claim 1; and (ii) a polyamide based
matrix; or (B) (i) a fire resistant formulation comprising the IOH
defined in claim 1 and one or more flame retardants; and (ii) a
polyamide based matrix.
44. A formulation according to claim 43, in which the polyamide
based matrix comprises generic groups with repeat units based on
amides selected from Nylon4, Nylon6, Nylon7, Nylon 11, Nylon12,
Nylon46, Nylon66, Nylon 68, Nylon610, Nylon612 and aromatic
polyamides and co-polymers, blends or alloys thereof.
45. A formulation according to claim 43, in which the polyamide
based matrix is selected from Nylon12, Nylon6 and Nylon66 and
co-polymers, alloys or blends thereof.
46. A formulation according to claim 43, which further comprises
one or more additives.
47. A formulation according to claim 46, in which the additives are
selected from polymeric stabilisers; lubricants; antioxidants;
pigments, dyes or other additives to alter the materials optical
properties or colour; conductive fillers or fibers; release agents;
slip agents; plasticisers; antibacterial or fungal agents; and
processing agents.
48. A formulation according to claim 47, in which the polymeric
stabiliser is a UV, light or thermal stabilizer.
49. A formulation according to claim 47, in which the processing
agents are selected from dispersing reagents, foaming or blowing
agents, surfactants, waxes, coupling reagents, rheology modifiers,
film forming reagents and free radical generating reagents.
50. A formulation according to claim 43, in which the polyamide
based matrix is Nylon12, Nylon6 and/or Nylon66; the IOH is
montmorillonite or hectorite modified with melamine hydrochloride
and/or melamine cyanurate hydrochloride and/or melamine and/or
melamine cyanurate; and the flame retardant is melamine cyanurate
and/or magnesium hydroxide; and the additive is a processing agent
and/or a polymeric stabiliser.
51. A formulation according to claim 46, in which the polyamide
based matrix is present in an amount of about 45 to about 95% w/w,
the IOH is present in an amount less than about 25% w/w and the
flame retardant and/or additives are present in an amount less than
about 30% w/w.
52. A formulation according to claim 46, in which the polyamide
based matrix is present in an amount greater than about 75% w/w,
the IOH is present in an amount less than about 3% w/w, the
melamine cyanurate flame retardant is present in an amount of about
11 to about 15% w/w and additives are present in an amount of about
less than about 4% w/w.
53. A formulation according to claim 46, in which the polyamide
based matrix is present in an amount greater than about 75% w/w,
the IOH is present in an amount less than about 3% w/w, the
melamine cyanurate flame retardant is present in an amount of about
11 and about 15% w/w, magnesium hydroxide flame retardant present
in an amount of about 1 and about 5% w/w and additives are present
in an amount less than about 4% w/w.
54. A method for the preparation of the polyamide fire resistant
formulation defined in claim 43, which comprises dispersing an
inorganic-organic hybrid (IOH) comprising: (i) an expandable or
swellable layered inorganic components and (ii) an organic
component including at least one ionic organic component and one or
more neutral organic components which are intercalated between
and/or associated with the layer(s) of the inorganic component, the
ionic or neutral organic components being capable of decomposing or
subliming endothermically, and/or releasing volatiles with low
combustibility on decomposition and/or inducing charring of organic
species during thermal decomposition or combustion and optionally
including one or more fire retardants into the polyamide based
matrix in one or more steps.
55. A method according to claim 54, in which at least some of the
components are ground prior to mixing.
56. A method according to claim 55, in which the components are
ground to a particle size less than about 200 microns.
57. A method according to claim 55, in which dispersion is achieved
using melt, solution or powder processing.
58. A method according to claim 55, in which the dispersion is
achieved using melt processing in a single or twin screw extruder,
batch mixer or continuous compounder.
59. A method according to claim 58, in which the melt processing is
conducted in a twin screw extruder.
60. A method according to claim 54, in which the dispersion occurs
at a sufficient shear rate, shear stress and residence time to
disperse the IOH at least partially on a nanometer scale.
61. A fire resistant article or parts thereof which is composed
wholly or partly of the IOH as defined in claim 1.
62. A fire resistant article or parts thereof as defined in claim
61, which is used in transport, building, construction, electrical
or optical applications.
63. A fire resistant article or parts thereof as defined in claim
62, in which the transport application is air, automotive,
aerospace or nautical.
64. A fire resistant article or parts thereof as defined in claim
61, which is a hollow article or sheet.
65. A fire resistant article or parts thereof as defined in claim
61 which is selected from pipes, ducts, fabric, carpet, cables,
wires, fibres, Environmental control systems, stowage bin hinge
covers, cable trays, ECS duct spuds, latches, brackets, passenger
surface units and thermoplastic laminate sheet.
66. A fire resistant hollow article or parts thereof which is
composed wholly or partly of the fire resistant formulation defined
in claim 52 and manufactured by rotational moulding or
extrusion.
67. A fire resistant fibre, fabric, carpet or parts thereof which
is composed wholly or partly of the fire resistant formulation
defined in claim 52 and manufactured by melt spinning or
extrusion.
68. A fire resistant article or parts thereof which is composed
wholly or partly of the formulation defined in claim 52 and
manufactured by sintering.
69. A fire resistant article or parts thereof which is composed
wholly or partly of the fire resistant formulation defined in claim
52 and manufactured by injection or compression moulding.
70. (canceled)
71. (canceled)
Description
[0001] The present invention relates to inorganic-organic hybrids
(IOHs), methods for their preparation and their use as fire
resistant materials or components of fire resistant materials. More
specifically, the invention relates to polyamide fire resistant
formulations containing IOHs which have application in the
production of fire resistant articles or parts thereof for use in
the transportation, building, construction and electrical or
optical industries.
BACKGROUND OF THE INVENTION
[0002] Materials based on organic polymeric systems (plastics) are
widely used in the transportation, building and construction
industries. A drawback of many types of organic polymers is
flammability which limits their suitability in applications
requiring flammability resistance and where regulatory authorities
govern flammability standards.
[0003] In commercially produced polymeric systems, flame-retarding
species may be added during processing or forming of the materials
to reduce the end products flammability. Conventional
flame-retardants may be divided into different categories
including:
[0004] Halogen based: which consist of either brominated or
chlorinated chemicals such as brominated polystyrene or phenylene
oxide (Dead Sea Bromine or Great Lakes CC) or
bis(hexachlorocyclopentadieno) cyclooctane (Occidental CC).
[0005] Phosphorus based: which consist of a range of different
chemistries from elemental phosphorus (Clarient), phosphonates
(A&W antiblaze 1045), phosphonate esters (Akzo Nobel),
phosphites, phosphates and polyphosphates including melamine
phosphite and phosphate, ammonium and melamine polyphosphate (DSM
Melapur).
[0006] Nitrogen based; such as melamine and its salts (U.S. Pat.
No. 4,511,684 Schmidt & Hoppe). Intumescent agents:
incorporating (i) an acid source (carbonization catalyst) such as
ammonium polyphosphate; (ii) a carbonization reagent e.g.
polyhydric alcohols such as pentaerythritol; and (iii) a blowing
reagent like melamine. Expandable graphite is also known to undergo
thermal expansion on addition of heat.
[0007] Inorganic additives: such as magnesium hydroxide and
aluminum hydroxide (Martinswerk), zinc borate (Fire Brake ZB, US
Borax) and antimony trioxide.
[0008] Although the addition of fire retardants to polymeric
systems may improve their fire performance other important
properties are often adversely effected for example: [0009]
Mechanical performance [0010] Surface finish [0011] Durability
[0012] Rheology [0013] Stability [0014] Smoke generation [0015]
Toxicity [0016] Cost [0017] Recyclability
[0018] Furthermore, there has been considerable recent impetus to
reduce the use of some flame-retardant classes due to toxicological
or environmental concerns. Such legislation has placed pressure on
the use of halogenated compounds and certain metal oxide
synergists. Phosphorus-based flame-retardants such as phosphonates
and elemental (red) phosphorus are also undesirable due to their
regulation under chemical weapon acts and considerable
manufacturing danger.
[0019] As far back as 1965, Jonas (GB 1114,174) teaches that the
incorporation of organically modified clay into plastics reduces
melt dripping during combustion.
[0020] More recently it has been shown that under certain synthetic
or processing conditions, organically modified clay may be
nano-dispersed into polymeric materials to improve mechanical and
fire performance.
[0021] Okada et al, (U.S. Pat. No. 4,739,007 (1988) Toyota) teaches
that nylon 6 materials with improved mechanical and heat distortion
temperature can be prepared by adding suitably modified clay during
the synthesis of nylon 6.
[0022] In this case the growing nylon chains force apart the clay
platelets to form intercalated or exfoliated nanomaterial
structures (so called in `situ polymerisation` method).
[0023] A more commercially desirable method of nano-dispersing
modified clay is described by Maxfield, et al, (WO 93/04118 WO
93/04117 (1993) Allied Signal). Maxfield teaches that clay-plastic
nanomaterials with improved mechanical and heat distortion
performance may be prepared by subjecting functionalised clay and
molten plastics such as nylon6, nylon66 and PBT to shear
forces.
[0024] Others have investigated the fire performance of plastics
incorporating clay nano particles. Gilman has studied the fire
performance of nylon-nanomaterials prepared through the `in situ`
polymerisation pathway using cone calorimetry (Proc. 43. Int. SAMPE
Sympos., (1998), p1053-1066, Fire and Materials, 24, (2000),
p201-208, Applied Clay Science, 15, (1999), p31-49). Improved heat
release rates were achieved with the addition of commercially
modified clay, without increasing toxic gas or smoke generation.
Gilman teaches that the improved fire performance results from the
nanoparticles both mechanically stabilizing the char and enhancing
its barrier properties. Although Gilman's cone calorimetry tests
suggest improved performance in terms of a reduction in heat
release rate, no mention was made of other aspects of the materials
fire performance in common tests described by bodies such as ASTM
and FAA which are used to assess, regulate and qualify the fire
worthiness of materials.
[0025] Other groups have reported that traditional flame-retardants
and nano-dispersed clays can act synergistically to improve fire
performance.
[0026] Klatt (WO 98/36022, (1998) BASF) teaches that nylon
materials incorporating organically modified clay and red
phosphorus synergistically improve fire performance to produce a VO
rating in UL94 type vertical burn tests. However, such compositions
are undesirable due to the danger associated with handling of
elemental phosphorus.
[0027] Morton (WO 99/43747, (1999) General Electric Company)
teaches that in certain polyester blends, phosphorus based flame
retardants especially resorcinol diphosphate and organically
modified clay act synergistically to improve fire performance. No
mention, however, is made of other important aspect such as the
effect on mechanical performance, smoke and toxic gas emission.
[0028] Takekoshim (U.S. Pat. No. 5,773,502 (1998) General Electric
Company) teaches that conventional halogenated-Sb.sub.2O.sub.3
flame-retardant systems and organically modified clay can act
synergistically. Takekoshim claims that nano-dispersed clay allows
for reductions in the amount of Sb.sub.2O.sub.3 and halogenated
flame retardant required to maintain a VO rating in the UL 94
flammability test. Clearly any use of halogenated flame retardant
is undesirable.
[0029] Masaru, T (JP 10182141 (1998) Sumitoma, Chem. Co.) disclose
a fire resistant and thermally expandable material at temperatures
between 100 to 150.degree. C. whereby blowing reagents such as
those containing azo, diazo, azide or triazine compound are located
between the layers of the silicate. In many polymeric systems,
however, this flame retarding system is undesirable since they
require moulding or forming at temperatures between 100.degree. C.
to 150.degree. C. Inoue and Hosokawa (JP 10081510 (1998) Showa
Denko K.K.) investigated the use of fluorinated synthetic mica
exchanged with melamine (0.1-40%) and melamine salts (<10%) as a
means of flame proofing plastics in a two step extrusion process.
They claim that a VO rated Nylon6 (UL94 vertical burn test) was
achieved at a loading of 5 percent-modified mica when greater than
80% exfoliation occurred. The use of synthetic clays and multiple
step processing is clearly undesirable from a commercial viewpoint.
Inoue and Hosokawa do not disclose highly desirable chemistries and
methodologies associated with triazine based formulations which
effect mechanical and fire performance. Furthermore, they do not
disclose important methodologies to flame retarded thin parts known
by those in the art to be extremely difficult to render flame
resistant whilst simultaneously reducing toxic gas and smoke
generation during combustion.
[0030] In a later disclosure Inoue, H., and co-workers (U.S. Pat.
No. 6,294,599 (2001) Showa Denko K.K.) also teach that polyamides
reinforced with fibrous additives may be rendered flame resistant
through the addition of triazine-modified clay and additional flame
retardant. They describe a highly rigid flame-retardant polyamide
comprising a polyamide, silicate-triazine compound reinforcement
and flame retardant/adjunct. The poor rheological properties of
highly rigid polyamide formulations limit the inventions usefulness
in preparing components made by conventional processing techniques
such as rotational or blow moulding, that are complex or thin
walled or which require high ductility or impact performance.
[0031] Brown, S. C. et al (WO 00/66657, Alcan International)
disclose a polymeric material incorporating Cloisite
montmorillonite in combination with Al(OH).sub.3 for the production
of fire resistant cables. This strategy is clearly only suitable
for plastics that are processed at low temperatures considering
that Al(OH).sub.3 decomposes to release water vapor at temperatures
above approximately 190.degree. C.
[0032] Accordingly, there is a need for the development of new
flame retarding systems which both meet the performance criteria
associated with specific applications and address the above
concerns.
SUMMARY OF THE INVENTION
[0033] According to one aspect of the present invention there is
provided an inorganic-organic hybrid (IOH) which comprises:
[0034] (i) an expandable or swellable layered inorganic component;
and
[0035] (ii) an organic component including at least one ionic
organic component.
[0036] Preferably, the organic component of the IOH also includes
one or more neutral organic components which are intercalated
between and/or associated with the layer(s) of the inorganic
component.
[0037] According to another aspect of the present invention there
is provided a method for the preparation of the IOH defined above
which comprises mixing components (i) and (ii) defined above or
constituents thereof in one or more steps.
[0038] The present invention also provides the use of the IOH
defined above as a fire resistant material.
[0039] According to a further aspect of the present invention there
is provided a fire resistant formulation which comprises:
[0040] (i) the IOH defined above; and
[0041] (ii) one or more flame retardants.
[0042] According to a still further aspect of the present invention
there is provided a method for the preparation of the fire
resistant formulation defined above which comprises mixing
components (i) and (ii) as defined above or constituents thereof in
one or more steps.
[0043] The present invention also provides a polyamide fire
resistant formulation which comprises either:
[0044] (A) (i) the IOH defined above; and [0045] (ii) a polyamide
based matrix; or
[0046] (B) (i) the fire resistant formulation defined above; and
[0047] (ii) a polyamide based matrix.
[0048] The present invention further provides a method for the
preparation of the polyamide fire resistant formulation defined
above which comprises dispersing the IOH or the fire resistant
formulation defined above or constituents thereof into the
polyamide based matrix in one or more steps.
[0049] The IOH and/or fire resistant formulations of the present
invention may be used to produce fire resistant articles or parts
thereof.
[0050] Thus, the present invention provides a fire resistant
article or parts thereof which is composed wholly or partly of the
IOH and/or fire resistant formulations defined above.
[0051] The present invention also provides a method of preparing
the fire resistant article or parts thereof defined above which
comprises moulding or forming the IOH and/or fire resistant
formulations defined above.
DETAILED DESCRIPTION OF THE INVENTION
[0052] For the purposes of this specification it will be clearly
understood that the word "comprising" means "including but not
limited to", and that the word "comprises" has a corresponding
meaning. It should also be noted that for the purposes of this
specification the terms "swellable" and "expandable" relating to
the layered inorganic component are interchangeable.
[0053] The inorganic component is a swellable/expandable layered
inorganic based material, rendered positively (or negatively)
charged due to isomorphic substitution of elements within the
layers, such as, those based on a 1:1 layered silicate structure
such as kaolin and serpentine and a 2:1 layered silicate structure
such as phyllosilicates, talc and pyrophyllite.
[0054] Other useful layered minerals include layered double
hydroxides of the general formula Mg.sub.6Al.sub.3.4(OH).sub.18.8
(CO.sub.3).sub.1.7.H.sub.2O including hydrotalcites and
synthetically prepared layered materials including synthetic
hectorite, montmorillonite, fluorinated synthetic mica and
synthetic hydrotalcite.
[0055] The group consisting of naturally occurring or synthetic
analogues of phyllosilicates is particularly preferred. This group
includes smectite clays such as montmorillonite, nontronite,
beidellite, volkonskoite, hectorite, bentonite, saponite,
sauconite, magadiite, kenyaite, laponite, vermiculite, synthetic
micromica (Somasif) and synthetic hectorite (Lucentite). Other
useful layered minerals include illite minerals such as ledikite
and mixtures of illite minerals with said clay minerals.
[0056] Naturally occurring phyllosilicates such as bentonite,
montmorillonite, and hectorite are most preferred. Such
phyllosilicates with platelet thicknesses less than about 5
nanometers and aspect ratios greater than about 10:1, more
preferably greater than about 50:1 and most preferably greater than
about 100:1 are particularly useful.
[0057] The preferred inorganic materials generally include
interlayer or exchangable metal cations to balance the charge, such
as, alkali metals or alkali earth metals, for example, Na.sup.+,
K.sup.+, Mg.sup.2+ or Ca.sup.2+, preferably Na.sup.+. The cation
exchange capacity of the inorganic material should preferably be
less than about 400 milli-equivalents per 100 grams, most
preferably about 50 to about 200 milli-equivalents per 100
grams.
[0058] The organic component includes one or more ionic species
that may be exchanged with the exchangeable metal ions associated
with the inorganic component and optionally one or more neutral
organic species which are intercalated between and/or associated
with the layer(s) of the inorganic component and/or one or more
coupling reagents.
[0059] The term "associated with" is used herein in its broadest
sense and refers to the neutral organic component being attached to
the layer(s) of the inorganic component, for example, by secondary
bonding interactions, such as, Van der Waals interactions or
hydrogen bonding or trapped by steric limitation.
[0060] Suitable examples of ionic species include those that
contain onium ions such as ammonium (primary, secondary, tertiary
and quaternary), phosphonium or sulfonium derivatives of aliphatic,
aromatic or aryl-aliphatic amines, phosphines and sulfides.
[0061] Such compounds may be prepared by any method known to those
skilled in the art. For example, salts prepared by acid-base type
reactions with mineral or organic acids including hydrochloric,
sulfuric, nitric, phosphoric, acetic and formic acids, by
Lewis-acid-Lewis-base type reactions or by reaction with alkyl
halides to form quaternary salts for example using Menschutkin type
methodology.
[0062] Ionic or neutral compounds which are known to decompose or
sublime endothermically, and/or which release volatiles with low
combustibility on decomposition and/or induce charring of organic
species during thermal decomposition or combustion are particularly
preferred.
[0063] Suitable species include neutral or ionic derivatives of
nitrogen based molecules, such as, triazine based species, for
example, melamine, triphenyl melamine, melam
(1,3,5-triazine-2,4,6-triamine-n-(4,6-diamino-1,3,5-triazine-yl)),
melem ((-2,5,8-triamino-1,3,4,6,7,9,9b-heptaazaphenalene)), melon
(poly{8-amino-1,3,4,6,7,9,9b-heptaazaphenalene-2,5-diyl)imino}),
bis and triaziridinyltriazine, trimethylsilyltriazine, melamine
cyanurate, melamine phthalate, melamine phosphate, melamine
phosphite, melamine phthalimide, dimelamine phosphate, phosphazines
and/or low molecular weight polymers with triazine and phosphazine
repeat units or salts or derivatives of the above molecules
including onium ion derivatives or salts or derivatives of
isocyanuric acid, such as, isocyanuric acid, cyanuric acid,
triethyl cyanurate, melamine cyanurate, trigylcidylcyanurate,
triallyl isocyanurate, trichloroisocyanuric acid,
1,3,5-tris(2-hydroxyethyl)triazine-2,4,6-trione,
hexamethylenentetramine. melam cyanurate, melem cyanurate and melon
cyanurate.
[0064] Reagents known to induce charring of organic species include
derivatives of phosphoric acid or boric acid, such as ammonia
polyphosphate and melamine polyphosphate, melamine phosphate
ammonium borate.
[0065] In another embodiment of the invention, the preferred ionic
compounds may be optionally used in combination with other ionic
compounds, for example, those known to improve compatibility and
dispersion between the layered inorganic material and polymeric
matrices such as those described in WO 93/04118 for the preparation
of nanomaterials. Amphiphilic molecules that incorporate a
hydrophilic ionic group along with hydrophobic alkyl or aromatic
moieties are preferred.
[0066] One or more coupling reagents may also be associated with
the inorganic component. Suitable coupling reagents include
organically functionalised silanes, zirconates and titanates.
Examples of silane coupling reagents include tri-alkoxy, acetoxy
and halosilanes functionalised with amino, epoxy, isocyanate,
hydroxyl, thiol, mercapto and/or methacryl reactive moieties or
modified to incorporate functional groups based on triazine
derivatives, long chain alkyl, aromatic or alkylaromatic moieties.
Examples of zirconate and titanate coupling reagents include Teaz
and Titan1.
[0067] It is known in the art that metal cations or anions
associated with layered inorganic materials may be exchanged with
organic ions through ion exchange processes. In a typical process,
the layered inorganic material is first swollen or expanded in a
suitable solvent(s) prior to ion exchange and then collected from
the swelling solvent following agglomeration using methods such as
filtration, centrifugation, evaporation or sublimation of the
solvent. Ion exchange techniques with suitable molecules are known
to be a useful method of increasing the compatibility between clay
and organic polymeric binders, thus aiding dispersion of clay
platelets into polymeric based matrices on a nanometer scale.
[0068] We have discovered that the ion exchange process may be
optionally carried out in the presence of one or more types of
organic ion to produce an inorganic-organic hybrid with a plurality
of functions. Without wishing to limit the present invention, such
functions may include the presence of ions which promote
dispersion, compatibility and interactions with the plastic matrix
and ions useful to improve other properties such as fire
performance. Generally during ion exchange the organic ions are
added in molar excess of the ion exchange capacity of the inorganic
material, preferably less than about 10-fold excess, more
preferably less than about a 5-fold excess is required.
[0069] It has also been unexpectedly discovered that the ion
exchange processes may be carried out in the presence of functional
dissolved or partially dissolved neutral species. Without being
limited by theory, it is proposed that at least a portion of the
neutral species are trapped in the intergallery region or otherwise
associated with the layered inorganic material following ion
exchange. Such a process provides a useful mechanism of dispersing
neutral additives on a molecular level into plastics. Again without
being limited by theory, during melt processing at least partial
exfoliation of the inorganic-organic hybrid allows the neutral
molecules to diffuse away and become homogeneously dispersed with
the matrix on a molecular level. This has a major impact on the
performance of the resultant material since it is well known that
efficient dispersion of all components in a plastic formulation,
preferably on a nano- or molecular scale, is an important factor
for achieving optimum performance.
[0070] In another aspect of the invention, the IOH may be treated
prior, during or following ion exchange with one or more coupling
reagents as described above. The coupling reagents are derivatized
to improve, for example, the compatibility and interactions between
the inorganic phase and polymeric matrix or to attach other
desirable functionalities to the inorganic layered phase.
[0071] Suitable flame retardants which retard flame propagation,
heat release and/or smoke generation which may be added singularly
or optionally synergistically to the IOH include:
[0072] Phosphorus derivatives such as molecules containing
phosphate, polyphosphate, phosphites, phosphazine and phosphine
functional groups, for example, melamine phosphate, dimelamine
phosphate, melamine polyphosphate, ammonia phosphate, ammonia
polyphosphate, pentaerythritol phosphate, melamine phosphite and
triphenyl phosphine.
[0073] Nitrogen containing derivatives such as melamine, melamine
cyanurate, melamine phthalate, melamine phthalimide, melam, melem,
melon, melam cyanurate, melem cyanurate, melon cyanurate,
hexamethylene tetraamine, imidazole, adenine, guanine, cytosine and
thymine.
[0074] Molecules containing borate functional groups such as
ammonia borate and zinc borate.
[0075] Molecules containing two or more alcohol groups such as
pentaerythritol, polyethylene alcohol, polyglycols and
carbohydrates, for example, glucose, sucrose and starch.
[0076] Molecules which endothermically release non-combustible
decomposition gases, such as, metal hydroxides, for example,
magnesium hydroxide and aluminum hydroxide.
[0077] Expandable Graphite
[0078] The polyamide based matrix may be included in the fire
resistant formulation in pellet, granule, flake or powdered form.
Suitable polyamides comprise generic groups with repeat units based
on amides, such as, Nylon4, Nylon6, Nylon7, Nylon 11 and Nylon12,
Nylon46, Nylon66, Nylon 68, Nylon610, Nylon612 and aromatic
polyamides, for example, poly`m`phenyleneisophthalamine and
poly`p`phenylene'terephthalmamide.
[0079] It will be appreciated that the polyamide based matrix may
include co-polymers, blends and alloys. The co-polymers may be made
up of two or more different repeat units one of which is an amide.
Such co-polymers may be prepared by any suitable methods known in
the art, for example, at the point of initial polymerisation or
later through grafting or chain extension type reactions during
processing. The polyamide blends and alloys may be prepared using
any method known to those skilled in the art including melt or
solution blending. Blending or alloying the polyamide with other
polymers may be desirable to improve properties such as toughness,
modulus, strength, creep, durability, thermal resistance,
conductivity or fire performance.
[0080] Nylon12, Nylon6 and Nylon66 and their respective
co-polymers, alloys and blends are particularly preferred.
[0081] The polyamide formulation can also optionally contain one or
more additives known in the art of polymer processing, such as,
polymeric stabilisers, for example, UV, light and thermal
stabilisers; lubricants; antioxidants; pigments, dyes or other
additives to alter the materials optical properties or colour;
conductive fillers or fibers; release agents; slip agents;
plasticisers; antibacterial or fungal agents, and processing
agents, for example, dispersing reagents, foaming or blowing
agents, surfactants, waxes, coupling reagents, rheology modifiers,
film forming reagents and free radical generating reagents.
[0082] A particularly preferred formulation comprises
[0083] Nylon12, Nylon6 and/or Nylon66; montmorillonite modified
with melamine hydrochloride and/or melamine; melamine cyanurate
and/or melam
(1,3,5-triazine-2,4,6-triamine-n-(4,6-diamino-1,3,5-triazine-yl))
cyanurate, and/or melem
((-2,5,8-triamino-1,3,4,6,7,9,9b-heptaazaphenalene)) cyanurate
and/or melon
(poly{8-amino-1,3,4,6,7,9,9b-heptaazaphenalene-2,5-diyl)imino})
cyanurate; magnesium hydroxide; and one or more additives.
[0084] The polyamide formulation preferably contains a polyamide
based matrix in an amount of from about 50 to about 95% w/w, an IOH
in an amount less than about 25% w/w and optionally a flame
retardant and/or additives in an amount less than about 30% w/w,
but in some cases preferably above about 10% w/w.
[0085] It has been discovered that the IOH may be readily dispersed
into the polyamide based matrix during the compounding (mixing)
stage. Without wishing to be limited by theory, it is proposed that
ion exchange enhances the layered IOHs compatibility with
polyamides compared with unmodified inorganic layered
materials.
[0086] This heightened compatibility in combination with sufficient
mixing forces, appropriate mixing sequence, screw design and time
allows the organically modified platelets associated with the IOH
to be at least partially exfoliated into the polyamide and hence
dispersed at least partially on a nanometer scale. This process
also provides a useful mechanism of dispersing into the polyamide
any neutral molecules associated with the IOH on a molecular
level.
[0087] Dispersion of the various components of the fire resistant
formulation including the IOH is aided by grinding prior to mixing.
Grinding is achieved using any suitable grinding equipment
including ball mills, ring mills and the like. It is preferable
that the components including the IOH is ground to a particle size
less than about 200 microns, more preferably less than about 50
microns, most preferably less than about 20 microns. The hybrid
material may also be ground using specialty grinding equipment
allowing grinding to nanometer sizes.
[0088] Dispersion may be affected using any suitable melt, solution
or powder based mixing process allowing sufficient shear rate,
shear stress and residence time to disperse the IOH at least
partially on a nanometer scale. Such processes may be conducted
using milling procedures such as ball milling, in a batch mixer
using internal mixers, such as, Banbury and Brabender/Haake type
mixers, kneaders, such as, BUS kneaders, continuous mixing
processes including continuous compounders, high intensity single
and twin screw extrusion.
[0089] Melt processing is preferred and in a particularly preferred
embodiment, twin screw extruders with an L:D ratio of at least
about 24, preferably more than about 30 equipped with at least one
and preferably multiple mixing and venting zones are employed for
dispersion. Such screw configurations useful for dispersive and
distributive mixing are well known to those in the art. A
particularly useful system has been found to be that illustrated in
FIG. 1.
[0090] The components of the formulation may be added in any order
or at any point along the extruder barrel. Since polyamides are
susceptible to hydrolysis it is preferable that the components are
dried prior to processing and/or mechanisms to remove water vapor
such as vents or vacuum ports available during processing. In a
preferred embodiment, all of the components are added at one end of
the extruder. In another preferred embodiment, a polymeric binder
and optionally minor components are added at one end of the
extruder and the IOH and optionally minor components at a later
point/s. In still another preferred embodiment, the IOH portion of
the polymeric binder and optionally minor components are added at
one end of the extruder with the remaining portion of the polymeric
binder and optionally minor components are added at a later
point/s. Following extrusion the molten composition is cooled by
means of water bath, air knife or atmospheric cooling and
optionally cut into pellets.
[0091] Preferably all of the major and minor components of the
system can be combined in as few a mixing steps as possible, most
preferably in a single mixing step.
[0092] The moulding or forming of the polyamide formulation into
fire resistant articles or parts thereof can be carried out using
any method known to those in the art including processes such as
extrusion, injection moulding, compression moulding, rotational
moulding, blow moulding, sintering, thermoforming, calending or
combinations thereof.
[0093] In one embodiment of the invention the fire resistant
polyamide system containing the major and minor components is
moulded or formed into parts having wall thickness less than about
25 mm, preferably less than about 5 mm, most preferably less than
1.5 mm. Such parts include but are not limited to tubes, complex
moulded hollow parts, sheets and complex moulded sheets and other
complex objects that are moulded or formed using techniques, such
as, extrusion, injection moulding thermoforming and rotational
moulding.
[0094] In the simplest process, the article or part is directly
produced during compounding for example by locating a die at the
end of the extruder allowing the shape of the extrudate to be
modified as required.
[0095] Examples of such components include simple parts such as
film, tape, sheet, tube, rod or string shapes. The process may also
involve multiple layers of different materials one of which being
the said polymeric system built up by processes known to those in
the art including co-extrusion.
[0096] In another preferred embodiment, the formulation is moulded
or formed in a separate step using techniques such as injection,
compression or blow moulding. Such parts are generally more complex
in nature compared with parts formed by extrusion alone, their
design only limited by the requirements of the moulding
tool/process employed. Suitable examples include but are not
limited to stowage bin hinge covers, ECS duct spuds, latches,
brackets, passenger surface units and the like.
[0097] It is noted that for certain applications it may be
preferable that the fire resistant polyamide formulation is ground
to a powder. In such cases it has unexpectedly been found that
grinding of the said formulation using cryogenic or atmospheric
grinding techniques known to those in the art may be carried out
without significantly effecting the performance of the system. Such
moulding applications include selective laser sintering, rotational
moulding, and extrusion.
[0098] Suitable examples including but not limited to environmental
control systems (air-conditioning ducts) and the like.
[0099] In other preferred applications, the polymeric formulation
may be first formed into a sheet or film, for example, through
extrusion, blow moulding, compression moulding or calending. The
sheet may be subsequently moulded to a desired shape using
thermoforming techniques.
[0100] In yet another application, the sheet or film may be used to
prepare reinforced thermoplastic laminates with woven fabrics
prepared from surface modified or natural glass, carbon or aramid
using techniques such as compression moulding or resin
infusion/transfer. Again, the laminate sheet hence formed may be
further moulded to a desired shape using techniques such as
thermoforming.
[0101] Alternatively the formulation may be spun into fibres by any
method known to those skilled in the art. Such a process provides a
method for producing fire resistant fabrics, carpets and alike
[0102] The present invention is useful for producing polyamide
materials with favourable rheological properties for moulding
including thin or intricate articles or parts thereof which
maintain mechanical properties close to or exceeding that of the
virgin polyamide matrix and which show improved fire performance in
standard tests through resisting combustion by self-extinguishing
when ignited, limiting flame propagation, and generating low smoke
and toxic gas emissions. Such articles or parts thereof are useful
for applications which require superior fire performance and in
industries that are regulated for fire performance including
transport, for example, air, automotive, aerospace and nautical;
building and construction; and electrical or optical, for example,
cables, wires and fibres.
BRIEF DESCRIPTION OF THE DRAWINGS
[0103] In the examples, reference will be made to the accompanying
drawings in which:
[0104] FIG. 1 is a diagram showing the twin screw extruder screw
and barrel configuration;
[0105] FIG. 2 is a graph showing the XRD results and transmission
electron microscope (TEM) image for Example 7;
[0106] FIG. 3 is a graph showing the XRD results for Example 8;
[0107] FIG. 4 is a graph showing the XRD results for Example 9;
[0108] FIG. 5 is a graph showing XRD results for Example 17;
and
[0109] FIG. 6 is a picture of complex hollow fire resistant
components moulded with formulations 13 and 34.
EXAMPLES
[0110] The invention will now be described with reference to the
following non-limiting examples.
[0111] General Conditions & Reagents
[0112] Tables 1, 2 and 3 Outline General Reagents, Conditions &
Procedures associated with the examples. TABLE-US-00001 TABLE 1
Commercially Available Reagents Reagent Trade name Supplier
Montmorillonite - organic Cloisite 93A Southern Clay modified
Montmorillonite - organic Cloisite 30B Southern Clay modified
Montmorillonite Cloisite Na.sup.+ Southern Clay Synthetic Hectorite
Laponite Southern Clay Nylon12 Vestamid 9005 Degussa Nylon12 FR
(Flame Vestamid 7166 Degussa retarded) Polyetherimide Ultem 9075 GE
Plastics Nylon6 Akulon PA6 DSM Nylon66 Akulon PA66 DSM Cyanuric
acid Cyanuric acid Aldrich Melamine cyanurate Fyrol MC Akzo-Nobel
Melamine phosphate Fyrol MP Akzo-Nobel Melamine polyphosphate
Melapur 200 DSM Melapur Melamine Melamine Aldrich Pentaerythritol
Pentaerythritol Aldrich Magnesium hydroxide Magnifin Martinswerk
Ammonia polyphosphate Antiblaze MC Rhodia Pentaerythritol phosphate
NH-1197 Great Lakes Pentaerythritol phosphate NH-1511 Great Lakes
Blend Zinc borate Fire Brake ZB US Borax Zn Stearate Zincum
Baerlocher Ca Stearate Ceasit Baerlocher Int 38 Synthetic resin
AXEL LuWax Eas1 Ethylene co-polymer BASF Irganox b1171
Phosphite/hindered phenol CIBA blend
[0113] TABLE-US-00002 TABLE 2 Processing Equipment and Conditions
Equipment Type Twin screw Berstorff ZE 25 mm modular co-rotating
twin screw extruder coupled extruder to a Haake Rheocord motor
drive and torque cell for rheology measurement L:D ratio = 36:1
Screw and barrel configuration presented in FIG. 1, Screw speed 300
rpm Feed rate .about.1.2 Kg/hour Residence time average 2 min Flat
200.degree. C. temperature profile from throat to die (nylon12)
Flat 250.degree. C. temperature profile from throat to die (nylon6)
Flat 275.degree. C. temperature profile from throat to die
(nylon66) Batch Mixer Haake R3000 batch mixer connected to torque
rheological load cell, pneumatic ram, roller rotors Rotor speed - 5
min 60 rpm, 10 min 120 rpm Temperature 190.degree. C. Injection
Battenfeld 80 ton BA 800 CDC injection moulding machine Moulding
Temperature profile: Nylon12 Zone 1 2 3 Nozzle Die Temp (.degree.
C.) 215 220 225 225 70.degree. C. Nylon6 Zone 1 2 3 Nozzle Die Temp
(.degree. C.) 230 230 250 260 90.degree. C. Nylon 66 Zone 1 2 3
Nozzle Die Temp (.degree. C.) 260 260 280 290 90.degree. C. ASTM
test samples: Injection pressure gradient 800 to 600 bar, cavity
pressure 400 bar, Holding pressures 600 to 0 bar Cooling time 30
sec Cone Calorimetry Samples: Injection pressure gradient 950 to
650 bar, cavity pressure 325 bar, Holding pressures 650 to 0 bar
Cooling tine 60 sec Compression Assett 2.5 MPa pneumatic press, 45
cm platens, heating (400.degree. C.) and cooling Moulding Moulding
platen temperature 220.degree. C. nylon12 Moulding platen
temperature 260.degree. C. nylon6 Moulding platen temperature
290.degree. C. nylon66
[0114] TABLE-US-00003 TABLE 3 Characterization Techniques,
Conditions and Sample Preparations Equipment Type X-ray diffraction
Phillips PW 1729, CuK.sub..alpha.1 source .lamda. = 0.154 nm (XRD)
Powders were ground to a particle size of less than 100 micron,
Plastics were compression moulded (210.degree. C.) to a thickness
of 100 micron Transmission Hitachi H-7500 operating at an electron
potential of 120 kV Electron 100 nm thick sections were prepared by
ultra microtomy Microscopy (TEM) Differential Cryogenic TA 2920
MDSC employing Advantage Scanning software, 10.degree. C. and
20.degree. C./min ramp rate rates for heating and Calorimetry (DSC)
cooling for general thermal and glass transition respectively.
Calibrated against, Indium, distilled water, cyclohexane and
sapphire Powders were ground to a particle size of less than 100
micron. Plastics were compression moulded (210.degree. C.) to a
thickness of 100 micron with quench cooling, 5 mm diameter
specimens were punched from the moulded sheet Thermal Thermal
Sciences, PL-STA, referenced against Al.sub.2O.sub.3 Gravimetric
Heating rate ramp10.degree. C./min Analysis (TGA) Powders were
ground to a particle size of less than 100 micron Plastics were
compression moulded (210.degree. C.) to a thickness of 100 micron
with quench cooling, 4 mm diameter specimens were punched from the
moulded sheet Cone Calorimetry ASTM E 1354-92 Testing Modified from
the original Stanton-Redcroft model, employing CSIRO developed
software Radiant flux 35 kW/m.sup.2, 3 repeats per sample, ASTM
E1356 Following injection moulding, samples (100 .times. 100
.times. 6 mm) were conditions for 7 days at 23.degree. C. at 50%
RH. Heat release, smoke, mass loss and gas emission were measured
Radiant Panel Conducted as per FAA specification (DOT FAA/AR-0012)
& as outlined in ASTM E648-93a Specific Optical ASTM E662-93
for optical density with gas released by Density of smoke samples
during the test analyzed for HF, HCl, HCN, H.sub.2S, NO.sub.x,
Generated By HBr, PO.sub.4, SO.sub.2 combustion Solid Materials and
gas emission Vertical Burn Vertical burn tests according to UL94 or
FAA specifications. UL94 specification - One 10 sec application of
flame from a 10 mm burner to 125 .times. 12.3 .times. 3.2 mm
samples according to UL specifications 2000. Flame extinguish times
were monitored over at least 3 samples Extinguishing times, VO
<10 s, V1 <30 s, V2 <30 s Cotton Wool Ignition No No Yes
FAA (DOT FAA/AR-0012) and ASTM F501-93 12 s burn One 12 s
application of flame from a 10 mm burner to 300 .times. 75 mm
samples according to FAA specification 2000: sample thickness
specified Pass FAA test requirement: Flame extinguished <15 sec
Drip extinguished <5 sec Burn height <203 mm 60 s burn One 60
s application of flame from a 10 mm burner to 300 .times. 75 mm
samples according to FAA specification 2000 Pass FAA test
requirement: Flame extinguished <15 sec Drip extinguished <3
sec Burn height <150 mm Sample thickness specified IZOD Notched
Radmana ITR 2000 instrumented impact tester Impact Testing Izod
mode, Iact strain rate 3.5 .+-. 0.2 m/sec 10 repeats per sample,
ASTM 256 Following injection moulding, samples were stored for 24 h
in desiccated containers, notched according to the ASTM 256
standard and tested `dry as moulded standard deviation generally
less than 8% Tensile Testing Instron tensile testing apparatus
(5565) utilizing a 30 kN load cell, 50 mm/min strain rate 5 repeats
per sample as per ASTM D638 External extensometer used for
independent modulus measurements ASTM D5938 Following injection
moulding, samples were stored for 24 h in desiccated containers and
tested `dry as moulded Generally standard deviation less than 2%
for modulus and strength results MFI MFI testing was completed
according to ASTM D1238 standards employing 2.16 load at a
temperature of 235.degree. C., Employing a Davenport Melt Flow
Indexer apparatus Parallel Plate The viscosities of samples were
measured over a wide range of Rheology shear rate range of
10.sup.-2 to 10.sup.1 s.sup.-1 at 240.degree. C. Tests of shear
rate sweep were carried out using a shear strain-controlled
rheometer, RDA II (Rheometric Scientific Inc.). The test fixture
geometry used was 25 mm parallel-plate with a constant gap between
0.6-0.8 mm. The nitrogen gas was used to provide an inert testing
environment to reduce sample degradation due to oxidation of
samples.
Methods for Preparing Inorganic-Organic hybrids (IOH)--Examples
1-6
Example 1
Preparation of Melamine Hydrochloride Modified Montmorillonite
(IOH1)
[0115] Montmorillonite exchanged Na.sup.+ (Cation Exchange Capacity
(CEC)=92 meq/100 g) was suspended in 80.degree. C. DI water (2%
w/w) and mechanically stirred at 1500 rpm for 60 min. Melamine
monohydrochloride salt (1.4 mmol/100 g montmorillonite) was then
added to the solution and the resultant suspension allowed to cool
with continued stirring for a further 150 min. Following filtration
of the suspension, the precipitate was thoroughly washed with warm
DI water and then preliminary dried (60-80.degree. C.). The
resultant granular organically modified clay was ground to a
particle size of less than 50 micron and then further dried at
75.degree. C. prior to processing or analysis. TABLE-US-00004 XRD
(CuK.sub..alpha.1 source .lamda. = 0.154 nm) Melamine.cndot.HCl
modified Cation Na.sup.+ Montmorillonite XRD d.sub.001 1.10 nm 1.27
nm
[0116] Results indicate that with ion exchange montmorillonite's
intergallery spacing is increased from 1.10 nm to 1.27 nm. This
result is consistent with sodium ions being replaced by protonated
melamine ions in the intergallery region during ion exchange.
Example 2a
Preparation of Melamine Hydrochloride Modified Montmorillonite in
the Presence of Melamine (IOH2)
[0117] Montmorillonite exchanged Na.sup.+ (Cation Exchange Capacity
(CEC)=92 meq/100 g) was suspended in 80.degree. C. DI water (2%
w/w), melamine added (1.4 mmol/100 g montmorillonite) and the
solution mechanically stirred at 1500 rpm for 60 min. Melamine
monohydrochloride salt (1.4 mmol/100 g montmorillonite) was then
added to the solution and the resultant suspension allowed to cool
with continued stirring for a further 150 min. Following filtration
of the suspension, the precipitate was thoroughly washed with warm
DI water and then preliminary dried (60-80.degree. C.). The
resultant granular organically modified clay was ground to a
particle size of less than 50 micron and then further dried at
75.degree. C. prior to processing or analysis. TABLE-US-00005 XRD
(CuK.sub..alpha.1 source .lamda. = 0.154 nm) Melamine and
Melamine.cndot.HCl modified Cation Na.sup.+ montmorillonite XRD
d.sub.001 1.10 nm 1.39 nm
[0118] Results indicate that montmorillonite modified by melamine
hydrochloride in the presence of melamine has an expanded
intergallery spacing compared with both montmorillonite that is
modified with melamine hydrochloride or sodium ions alone. The
result is consistent association/entrapment of the neutral melamine
with the clay during ion exchange.
Example 2b
Preparation of Melamine Hydrochloride Modified Montmorillonite in
the Presence of Melamine (IOH2)
[0119] 3.0 Kg of sodium montmorillonite was dispersed into 200L
de-ionized water at 60.degree. C. with vigorous stirring (200 rpm)
adding the powder slowly over a period of approximately one hour to
assist wetting out of the individual particles/platelets. After the
suspension had stirred at that temperature for approximately 2
hours, an aqueous solution (35L) containing 1.39 Kg melamine and
0.92L HCl (9.65M) at 85.degree. C. was rapidly added whilst the
impeller speed was simultaneously increased to 300 rpm. After an
initial period of high viscosity whilst the modified
montmorillonite aggregated, the viscosity decreased and the clay
solution was allowed to stir for a further 3 hours at 60.degree. C.
Following filtration of the suspension the collected modified clay
was re-dispersed into de-ionized water (150L) and allowed to stir
for 1 hour at 60.degree. C. before an aqueous solution (10 L)
containing 0.385 Kg melamine and 0.26 L HCl (9.65M) at approx
85.degree. C. was added. At this point the mixture was stirred for
a further two hours before it was filtered. Next the modified clay
was re-dispersed into de-ionized water (150L) and stirred for a
further 1 hour at 60.degree. C. prior to filtration, drying and
grinding of the modified clay to a particle size less than 50
micron. TABLE-US-00006 XRD (CuK.sub..alpha.1 source .lamda. = 0.154
nm) Melamine and Melamine.cndot.HCl modified Cation Na.sup.+
Montmorillonite XRD d.sub.001 1.10 nm 1.40 nm
[0120] These results illustrate that the robustness of the
modification procedure to variation in mole ratio of
montmorillonite CEC to melamine salt and melamine and the reaction
conditions employed to carry out the modification procedure. This
result is consistent association/entrapment of the neutral melamine
with the clay during ion exchange.
Example 2c
Preparation of Melamine Hydrochloride Modified Montmorillonite in
the Presence of Melamine (IOH2)
[0121] 15.0 Kg of montmorillonite was dispersed into 200L deionized
water at 60.degree. C. with vigorous stirring (200 rpm) adding the
powder slowly over a period of approximately 2 hours to assist
wetting out of the individual particles/platelets. After the
suspension had stirred at that temperature for approximately 4
hours, an aqueous solution (50L) containing 2.78 Kg melamine and
1.84 L HCl (9.65 M) at 85.degree. C. was rapidly added whilst the
impeller speed was simultaneously increased to 300 rpm. After an
initial period of high viscosity whilst the modified
montmorillonite aggregated, the viscosity decreased and the clay
solution was allowed to stir for a further 3 hours at 60.degree. C.
Following filtration of the suspension the collected modified clay
was re-dispersed into de-ionized water (150L) and allowed to stir
for 1 hour at 60.degree. C. before an aqueous solution (25L)
containing 1.925 Kg melamine and 1.3 L HCl (9.65M) at approx
85.degree. C. was added. At this point the mixture was stirred for
a further two hours before it was filtered. Next the modified clay
was re-dispersed into de-ionized water (200L) and stirred for a
further 1 hour at 60.degree. C. prior to filtration, drying and
grinding of the modified clay to a particle size less than 50
micron. TABLE-US-00007 XRD (CuK.sub..alpha.1 source .lamda. = 0.154
nm) Melamine and Melamine.cndot.HCl modified Cation Na.sup.+
Montmorillonite XRD d.sub.001 1.10 nm 1.40 nm
[0122] Results illustrate the robustness of the modification
procedure to variation in reaction conditions employed to carry out
the modification procedure. This result is consistent with
association/entrapment of the neutral melamine molecules with the
clay during ion exchange.
Example 3
Preparation of Melamine Cyanurate hydrochloride modified
montmorillonite (IOH3)
[0123] Na.sup.+ exchanged montmorillonite (Cation Exchange Capacity
(CEC)=92 meq/100 g) was suspended in 95.degree. C. distilled water
(2% w/w), cyanuric acid added (1.4 mmol/100 g montmorillonite) and
the solution mechanically stirred at 1500 rpm for 60 min. Melamine
mono-hydrochloride salt
[0124] (1.4 mmol/100 g montmorillonite) was then added to the
solution and the resultant suspension with continued stirring for a
further 150 min. Following filtration of the suspension, the
precipitate was thoroughly washed with warm distilled water and
then preliminary dried (75.degree. C.). The resultant granular
organically modified clay was ground to a particle size of less
than 45 micron and then further dried at 60-80.degree. C. prior to
processing or analysis. TABLE-US-00008 XRD (CuK.sub..alpha.1 source
.lamda. = 0.154 nm) Melamine cyanurate.cndot.HCl modified Cation
Na.sup.+ montmorillonite XRD d.sub.001 1.10 nm 1.42 nm
[0125] Results from Example 3 indicate that the intergallery
spacing of montmorillonite is expanded further when exchanged with
melamine cyanurate ion compared with sodium ion or melamine ion
modified montmorillonite alone (Example 1) due to its larger size
and hence steric impact.
Example 4
Preparation of Melamine and Melamine Cyanurate Modified
Montmorillonite in Presence of Melamine and Melamine Cyanurate
(IOH4)
[0126] Montmorillonite exchanged Na.sup.+ (Cation Exchange Capacity
(CEC)=92 meq/100 g) was suspended in 95.degree. C. distilled water
(2% w/w), cyanuric acid added (1.4 mmol/100 g montmorillonite) and
the solution mechanically stirred at 1500 rpm for 60 min. Melamine
monohydrochloride salt (1.4 mmol/100 g montmorillonite) and
melamine (1.4 mmol/100 g montmorillonite) was then added to the
solution and the resultant suspension continued stirring for a
further 150 min. Following filtration of the suspension, the
precipitate was thoroughly washed with warm distilled water and
then preliminary dried under vacuum (75.degree. C.). The resultant
granular organically modified clay was ground to a particle size of
less than 45 micron and then further dried at 60-80.degree. C.
prior to processing or analysis. TABLE-US-00009 XRD
(CuK.sub..alpha.1 source .lamda. = 0.154 nm) Melamine and Melamine
cyanurate.cndot.HCl Cation Na.sup.+ modified montmorillonite XRD
d.sub.001 1.10 nm 1.53 nm
[0127] The results from Example 4 indicate that the intergallery
spacing of montmorillonite exchanged with melamine cyanurate ion in
the presence of melamine and melamine cyanurate is larger than both
sodium ion or melamine cyanurate ion exchanged montmorillonite
alone (Example 3). This result is consistent with
association/entrapment of the neutral melamine and melamine
cyanurate with the clay during ion exchange.
Example 5
Preparation of Melamine and Trimethyl Cetylammonium and Melamine
Hydrochloride Modified Montmorillonite (IOH5)
[0128] Montmorillonite exchanged Na.sup.+ (Cation Exchange Capacity
(CEC)=92 meq/100 g) was suspended in 90.degree. C. distilled water
(2% w/w), and the solution mechanically stirred at 1500 rpm for 60
min. Melamine monohydrochloride salt (1.4 mmol/100 g
montmorillonite) and trimethylcetylammoniun chloride (1.4 mmol/100
g montmorillonite) was then added to the solution and the resultant
suspension allowed to cool with continued stirring for a further
150 min. Following filtration of the suspension, the precipitate
was thoroughly washed with warm distilled water and then
preliminary dried under vacuum (75.degree. C.). The resultant
granular organically modified clay was ground to a particle size of
less than 45 micron and then further dried at 60-80.degree. C.
prior to processing or analysis. TABLE-US-00010 XRD
(CuK.sub..alpha.1 source .lamda. = 0.154 nm) Cation XRD d.sub.001
Na.sup.+ 1.10 nm Trimethylcetylammonium chloride 1.84 nm Melamine
and Trimethylcetylammonium chloride 1.68 nm modified
montmorillonite
[0129] The results from Example 5 indicate that the intergallery
spacing of montmorillonite exchanged with both
trimethylcetylammonium chloride and melamine hydrochloride is
larger than sodium but smaller than trimethylcetylammonium ion
exchanged montmorillonite. This result is consistent with
trimethylcetylammonium chloride and melamine hydrochloride being
present in the intergallery spacing of the modified
montmorillonite.
Example 6
Preparation of Melamine and Melamine Hydrochloride Modified
Synthetic Hetorite, Laponite (IOH6)
[0130] Hectorite clay (Synthetic Laponite RD) was modified using
the same general procedure as employed in Example 2 taking into
consideration its lower cation exchange capacity (CEC) of 55
mmol/100 g and employing a 1% solution for modification. Strict
control was placed over the mole ratio of hectorite CEC and
melamine salt to encourage platelet agglomeration. Following
treatment with the melamine salt/melamine, the modified synthetic
clay was separated from the treatment solution by filtration.
TABLE-US-00011 XRD (CuK.sub..alpha.1 source .lamda. = 0.154 nm)
Melamine and Melamine.cndot.HCl Modified Cation Na.sup.+/Li.sup.+
Hectorite XRD d.sub.001 1.20 nm 1.33 nm
[0131] The results from Example 6 indicate that the intergallery
spacing of synthetic hectorite exchanged with melamine
hydrochloride in the presence of melamine is larger than sodium
changed montmorillonite.
[0132] Melt Dispersion of Components and Formulation of Fire
resistant Materials Examples 7-20
[0133] While each of the following examples use Nylon12, Nylon6 or
Nylon66 as the polyamide based matrix, the person skilled in the
art will appreciate that the examples for fire retarding nylon12,
nylon6 and nylon66 are also applicable to other types of
polyamides, polyamide co-polymers, polyamide blends, alloys and the
like.
[0134] The Formulation Constituents Employed in Examples 7 to 20
are provided in Tables 4a to 4e. TABLE-US-00012 TABLE 4a
Formulations used in Examples 7 to 20 Formu- Ny- Cloisite Cloisite
Cloisite IOH2 Melamine lation lon12 Na.sup.+ 30B 93A (Example2)
Cyanurate 1 99.25 0.75 2 98.5 1.5 3 95 5.0 4 93 7.0 5 95 5 6 95 5 7
82 3 15 8 83.5 1.5 15 9 84.25 0.75 15 10 85 15 11 82 3 15 12 83.5
1.5 15 13 84.25 0.75 15 14 84.5 3 12.5 15 86 1.5 12.5 16 86.75 0.75
12.5 17 87 3 10 18 88.5 1.5 10 19 89.25 0.75 10 20 90.5 3 7.5 21 91
1.5 7.5 22 91.75 0.75 7.5
[0135] TABLE-US-00013 TABLE 4b Formulations used in Examples 7 to
20 Magnesium Melamine Ammonia IOH2 Melamine Hydroxide Melamine poly
Melamine poly Pentaerythritol Pentaerythritol Formulation Nylon12
(Example 2) Cyanurate (H7) phosphate phosphate phthalate phosphate
phosphate phosphate blend 23 83.5 1.5 15 24 83.5 1.5 15 25 83.5 1.5
15 26 83.5 1.5 15 27 83.5 1.5 15 28 83.5 1.5 15 29 83.5 1.5 15 30
83.5 1.5 10 5 31 87.5 12.5 32 98.5 1.5
[0136] TABLE-US-00014 TABLE 4c Formulations used in Examples 7 to
20 Magnesium Magnesium IOH2 Melamine Magnesium Magnesium hydroxide
hydroxide Formulation Nylon12 (Example 2) cyanurate hydroxide (H7)
hydroxide (H10) (H5iv) (H10iv) 33 82 3 12.5 2.5 34 83.5 1.5 12.5
2.5 35 84.25 0.75 12.5 2.5 36 82 3 10 5 37 84.25 0.75 10 5 38 82 3
7.5 7.5 39 83.5 1.5 7.5 7.5 40 84.25 0.75 7.5 7.5 41 83.5 1.5 12.5
2.5 42 83.5 1.5 12.5 2.5 43 83.5 1.5 12.5 2.5
[0137] TABLE-US-00015 TABLE 4d Formulations used in Examples 7 to
20 IOH1 IOH2 IOH4 IOH5 Melamine Formulation Nylon12 Nylon6 Nylon66
(Example 1) (Example 2) (Example 4) (Example 5) cyanurate 44 88.5
1.5 10 45 83.5 1.5 15 46 88.5 1.5 10 47 83.5 1.5 15 48 84.25 0.75
15 49 84.25 0.75 15 50 84.25 0.75 15
[0138] TABLE-US-00016 TABLE 4e Formulations used in Examples 7 to
20 IOH2 Melamine Calcium Zinc Luwax Formulation Nylon12 (Example 2)
cyanurate stearate Stearate Int38 EAS1 Irganox 51 83.25 0.75 15 1
52 82.25 0.75 15 2 53 83.25 0.75 15 1 54 82.25 0.75 15 2 55 82.25
0.75 15 2 56 82.25 0.75 15 2 57 83.75 0.75 15 0.5
Example 7
Processing Rheology (Table 5), XRD & TEM (FIG. 2), Mechanical
(Table 6) and Fire Performance (Tables 7 & 8) of Nylon12
Modified with Commercially Available Clay During Melt
Processing
[0139] The following example indicates that the processing rheology
of Nylon 12 is not affected by the melt dispersion of commercially
available `organoclay` at least partially on a nanometer scale
(XRD). This dispersion results in improved mechanical performance
and heat release rate as determined by cone calorimetry but poor
performance compared with conventional flame retarded
nylon12(Nylon12 FR) in terms of vertical burn results which is a
primary tool used to discriminate material fire performance by
governing bodies such as UL, AS.TM., FAA and the like. As such
these materials do not meet such performance standards
TABLE-US-00017 TABLE 5 Torque Rheology Extrusion Torque Rheology
Formulation Nylon12 1 2 3 4 Torque (Nm) 105 100 95 91 87 Batch
mixer torque rheology Formulation Nylon12 3 5 6 Torque (Nm) 47 44
47 49
[0140] TABLE-US-00018 TABLE 6 Mechanical Performance Nylon12
Formulation Nylon12 FR 1 2 3 4 Modulus (MPa) 1110 1712 1187 1227
1470 1700 Tensile 36 48 53 52.3 57 44.6 Strength (MPa) Impact
(k/m.sup.2) 4006 2200 6200 8100 6700 3700
[0141] TABLE-US-00019 TABLE 7 Fire Testing Cone Results Peak Heat
Mass Loss SEA Rel.sup.d Rate Co Prod.sup.n CO.sub.2 Prod.sup.n
(Smoke) Formulation kW/m.sup.2 g/m.sup.2s Kg/Kg Kg/Kg m.sup.2/Kg
Nylon 12 FR 1800 18.6 0.01 1.2 100 Nylon12 1344 17.1 0.03 1.6 385 1
740 13.3 0.01 1.0 360 2 620 12.8 0.02 1.5 382 3 536 10.8 0.02 1.5
382 4 447 10.0 0.02 1.5 410
[0142] TABLE-US-00020 TABLE 8 Vertical Burn Results Formulation
UL94 (3.2 mm) FAA (1.6 mm) Nylon 12 FR VO Pass Nylon12 LV HB Fail 1
V2 Fail 2 V2 Fail 3 V1 Fail 4 V1 Fail
Example 8
Processing (Table 9), XRD (FIG. 3), mechanical (Table 10) and fire
performance (Table 11-14) of nylon12 modified with commercially
available clay and flame retarding additives (melamine cyanurate)
during melt processing
[0143] The following example indicates that the processing rheology
of Nylon 12 is not effected by the melt dispersion of commercially
available `organoclay` at least partially on a nanometer scale
(XRD) and flame retardant. This dispersion results in improved
mechanical performance reduced heat release results via cone
calorimetry and vertical burn performance for specimens greater
than 1.6 mm thickness compared with conventionally flame retarded
nylon12. Although samples of 0.75 mm thickness provide good smoke
and toxic gas release results they fail FAA type 12 sec vertical
burn testing and perform badly in radiant panel tests. This
indicates that the strategy is not satisfactory to meet the
performance of thin parts to the performance requirements of
governing bodies such as the FAA. TABLE-US-00021 TABLE 9 Processing
Rheology Formulation Torque (Nm) Nylon 12 105 7 102 8 104 9 107
[0144] TABLE-US-00022 TABLE 10 Mechanical Performance Tensile
Tensile Modulus Strength Elongation Notched Impact Formulation
(MPa) (MPa) at break (%) Strength (J/m.sup.2) Nylon12 1110 36 640
4600 Nylon12 FR 1712 48.1 77 2100 7 1505 38.5 54 3100 8 1471 38.1
222 4100 9 1380 38.1 291 4600 Standard Deviation - Modulus < 4%,
Strength < 3%, Elongation < 10%, Impact < 11%
[0145] TABLE-US-00023 TABLE 11 Fire Testing Cone Calorimetry Peak
Mass Loss SEA Heat Rel.sup.d Rate CO Prod.sup.n CO.sub.2 Prod.sup.n
(Smoke) Formulation kW/m.sup.2 g/m.sup.2s Kg/Kg Kg/Kg m.sup.2/Kg
Nylon12 FR 1800 18.6 0.01 1.2 100 Nylon12 1344 17.1 0.03 1.6 385 7
670 13.9 0.01 1.6 220 8 695 14.1 0.01 1.6 240 9 782 16.1 0.01 1.7
280
[0146] TABLE-US-00024 TABLE 12 Vertical Burn Results UL94 FAA 12s
FAA 12s Formulation (3.2 mm) (1.6 mm) (0.75 mm) Nylon 12 FR V0 Pass
Fail Nylon12 HB Fail Fail 7 V0 Pass Fail 8 V0 Pass Fail 9 V0 Pass
Fail
[0147] TABLE-US-00025 TABLE 13 Vertical Burn, Radiant Panel and
Smoke Test Results (0.75 mm) FAA 12s Smoke Formulation (0.75 mm) Ds
Radiant Panel 9 Fail 4.88 Full length burn 8 Fail 11.86 Full length
burn 7 Fail 21.45 Full length burn
[0148] TABLE-US-00026 TABLE 14 Toxic Gas Emission Toxic Gas
Formulation (ppm) 9 8 7 HF 3 3 5 HCl 1 1 3 HCN 4 4 4 H.sub.2S -- --
-- NO.sub.x 2 2 1 HBr 1 1 1 PO.sub.4 -- -- -- SO.sub.2 1 1 1
Example 9
Processing Rheology (Table 15), XRD (FIG. 4), Mechanical (Table 16)
and Fire Performance (Table 17-19) of Nylon12 Modified with IOH2
Incorporating Montmorillonite Modified with Melamine
Hydrochloride/Melamine and Flame Retarding Additives (Melamine
Cyanurate) During Melt Processing
[0149] The following example indicates that the processing rheology
of Nylon 12 is not effected by the melt dispersion of IOH2 and
flame retardant at least partially on a nanometre scale (XRD). Such
dispersion results in improved mechanical and vertical burn results
compared with conventionally flame retarded nylon12. Samples of
0.75 mm provide good smoke and toxic gas release results, pass FAA
type 12s vertical burn tests and perform better in radiant panel
tests. It is known to those in the art that flame retarding thin
polymeric based materials is much more difficult than flame
retarding thicker materials and as such meeting performance
requirements at thin thickness is an indication of superior fire
retarding performance. TABLE-US-00027 TABLE 15 Processing Rheology
Extruder Torque Formulation (Nm) Nylon 12 105 11 105 12 106 13
103
[0150] TABLE-US-00028 TABLE 16 Mechanical Performance Tensile
Tensile Modulus Strength Elongation at Notched Impact Formulation
(MPa) (MPa) break (%) Strength (J/m.sup.2) Nylon12 1110 36 640 4600
Nylon12 FR 1712 48.1 77 2100 11 1443 39.7 140 3900 12 1398 39.0 215
4200 13 1349 38.9 375 4700 Standard Deviation - Modulus < 3%,
Strength < 3%, Elongation < 8%, Impact < 9%
[0151] TABLE-US-00029 TABLE 17 Fire Performance - Vertical Burn
UL94 12s FAA 12s FAA 60s FAA Formulation (3.2 mm) (1.6 mm) (0.75
mm) (0.75 mm) Nylon12 FR VO Pass Fail Fail Nylon12 HB Fail Fail
Fail 11 V0 Pass Pass Pass 12 V0 Pass Pass Pass 13 V0 Pass Pass
Pass
[0152] TABLE-US-00030 TABLE 18 Fire Performance (0.75 mm) FAA 12 s
Vertical Burn Radiant Panel Extinguishment time Extinguishment Burn
length Smoke time & Formulation Drip Extinguishment time Ds
Burn length 11 4.9 s 6.79 5 sec 46 mm 25 mm 0 s 12 2 s 9.83 3 sec
19 mm 25 mm 0 s 13 0 s 3.31 1 sec 21 mm 12.5 mm 0 s
[0153] TABLE-US-00031 TABLE 19 Toxic Gas Emission Toxic Gas
Emission Formulation (ppm) 13 12 11 HF 6 4 3 HCl 1 1 1 HCN 8 7 7
H.sub.2S -- -- -- NO.sub.x 3 2 2 HBr 1 1 1 PO.sub.4 -- -- --
SO.sub.2 1 1 1
Example 10
The Following Example Illustrates the Effect of Different
Processing Parameters on the Mechanical Performance (Table 20) and
Vertical Burn Performance (Table 21) of Formulation 13 which
Incorporates IOH2+ Conventional Flame Retardant Melamine
Cyanurate
[0154] Results indicate the robustness of the formulation in terms
of mechanical and fire performance to different processing
conditions such as through-put, temperature profile, screw speed
for the given screw and barrel configuration provided in FIG. 1.
TABLE-US-00032 TABLE 20 Mechanical Performance Conditions Notched
Processing Screw Tensile Tensile Impact Temp. speed Through-
Modulus Strength Strength (.degree. C.) (rpm) put (Kg/h) (MPa)
(MPa) (J/m.sup.2) 180 300 1.5 1300 37.6 5100 190 300 1.5 1420 37.9
5300 200 300 1.5 1420 38.4 4800 210 300 1.5 1520 38.8 4600 200 150
1.5 1500 37.7 5300 200 400 1.5 1530 39.6 4100 200 300 15 1540 39.4
4100 Standard Deviation - Modulus < 3%, Strength < 3%, Impact
< 9%
[0155] TABLE-US-00033 TABLE 21 FAA 12 s Vertical Burn Performance
(0.75 mm thickness) Conditions Screw Flame out Processing speed
Through-put Time Temp.(.degree. C.) (rpm) (Kg/h) Result (sec) 180
300 1.5 Pass 5 190 300 1.5 Pass 4 200 300 1.5 Pass 2 210 300 1.5
Pass 6 200 150 1.5 Pass 2 200 400 1.5 Pass 7 200 300 15 Pass 3
Example 11
The Following Example Illustrates the Effect of Different IOH2
(Example 2) and Melamine Cyanurate Concentrations on Mechanical and
Vertical Burn Performance of Nylon12 (Table 22)
[0156] Results indicate that preferably more than 10% melamine
cyanurate is required to pass FAA 12 s vertical burn test
requirements at 0.75 mm thickness. Results also indicate that
unlike classically flame retarded nylon12 this fire performance is
achievable whilst maintaining excellent mechanical properties
relative to nylon12. TABLE-US-00034 TABLE 22 Performance of
Formulations incorporating different concentrations of IOH2 and
Melamine cyanurate Tensile Tensile Notched FAA 12 s Vertical
Modulus Strength Impact burn (0.75 mm) Formulation (MPa) (MPa)
Strength (J/m.sup.2) Ext. Time (s) Nylon12 1100 36 4600 Fail (62)
Nylon12 FR 1712 48.1 2100 Fail (24) 11 1443 39.7 3900 Pass (5) 12
1398 39.0 4200 Pass (5) 13 1349 38.9 4700 Pass (2) 14 1480 37.9
4200 Pass (14) 15 1410 39.4 4400 Pass (7) 16 1386 40.1 4800 Pass
(6) 17 1483 37.9 3900 Fail (18) 18 1476 39.4 5050 Fail (19) 19 1404
40.1 5200 Fail (19) 20 1445 37.8 4200 Fail (32) 21 1420 39.7 4500
Fail (28) 22 1361 40.1 5200 Fail (32)
Example 12
The Following Example Illustrates the Effect of Different
Conventional Flame Retardants on the Performance (Table 23) of
Nylon12 Incorporating an IOH2 (Example 2)
[0157] The results presented in Table 23 demonstrate that materials
incorporating the IOH and melamine cyanurate provide both excellent
mechanical and fire performance. Formulations containing melamine
phthalate and pentaerythritol phosphate also provide excellent fire
performance with lower mechanical performance. Samples containing
IOH with melamine cyanurate and Mg(OH).sub.2 provide the excellent
mechanical performance in terms of impact, modulus, and strength
also excellent vertical burn performance. TABLE-US-00035 TABLE 23
Performance of formulations incorporation IOH2 and various
conventional flame retardants Notched FAA 12 s Tensile Tensile
Impact vertical burn Modulus Strength Strength (0.75 mm) UL 94
Formulation (MPa) (MPa) (J/m.sup.2) Ext. Time (sec) 3.2 mm 12 1460
39 4800 Pass (2) V0 23 1500 41 3900 Fail (31) V2 24 1540 41.9 2500
Fail (26) V2 25 1500 40.4 3000 Fail (29) V2 26 -- -- -- Pass (7) V0
27 1410 41.0 4100 Fail (24) V2 28 1420 43.5 1500 Fail (32) V2 29
1160 43.6 800 Pass (10) V0 30 1628 43.6 4800 Pass (4) V0
Example 13
The Following Example Illustrates the Effect of Removing Components
of the Fire Resistant Formulation on Resultant Fire Performance
(Table 24)
[0158] The results indicate that removal of either the modified
inorganic-organic hybrid or melamine cyanurate from the formulation
provides unsatisfactory vertical burn performance following FAA 12
s type testing at 0.75 mm thickness. TABLE-US-00036 TABLE 24 FAA
type Vertical Burn Performance (0.75 mm) Formulation Ext. Time (s)
FAA requirement Nylon12 65 .+-. 9 Fail 31 31 .+-. 4 Fail 32 32 .+-.
13 Fail 15 7 .+-. 4 Pass
Example 14
The Following Example Illustrates the Mechanical and 12s Vertical
Burn Performance (Table 25) and Cone Calorimetry Results (Table 26)
of Nylon12 Formulations Prepared with IOH2 (Example 2), Melamine
Cyanurate and Magnesium Hydroxide. Table 27 provides Radiant Panel,
Smoke, and 60s FAA Type Vertical Burn Results for the Above
Mentioned Formulations. Mechanical and Vertical Burn Performance of
Nylon 12 Formulations Incorporating IOH2, Melamine Cyanurate and
Magnesium Hydroxide of Different Surface Functionality and Particle
Size Distribution is Provided in Table 28.
[0159] Results from Example 14 show that excellent processability,
mechanical, vertical burn, and heat release results are obtainable
with formulations incorporating IOH2, melamine cyanurate and low
concentrations of magnesium hydroxide in particular formulations
incorporating IOH dispersed at least partially on a nanometre
scale, melamine cyanurate and 2.5% magnesium hydroxide which
provides excellent mechanical, vertical burn and peak and average
heat release results. The results also indicate that Mg(OH.sub.2)
of different grades may be employed in conjunction with IOH2 and
melamine cyanurate to produce formulations with excellent
processability, mechanical and fire performance. TABLE-US-00037
TABLE 25 Mechanical Performance of nylon materials with various
amounts of IOH2 and conventional flame retardants Notched FAA 12 s
Tensile Tensile Impact Vertical burn MFI Modulus Strength Strength
Ext. Time (s) Formulation (g/min) (MPa) (MPa) (J/m.sup.2) (0.75 mm)
Nylon12 44 1100 36 4600 Fail (62) Nylon12 FR 32 1712 48.1 2100 Fail
(24) 33 12.6 1470 41.8 4500 Fail (18) 34 12.0 1460 41.1 4700 Pass
(10) 35 11.5 1430 39.9 5200 Pass (9) 36 13.4 1578 43 3800 Pass (6)
30 13.5 1509 42 4800 Pass (4) 37 13.5 1543 40.5 5300 Pass (6) 38
13.4 1529 41 3900 Fail (41) 39 13 1520 40.6 4200 Fail (19) 40 13.1
1510 41.6 4600 Pass (4)
[0160] TABLE-US-00038 TABLE 26 Cone Calorimeter Heat Release
Results Peak Heat 300 s Average Release Heat Release Formulation
(kW/m.sup.2) (kW/m.sup.2) Nylon12 1100 748 Nylon12 FR 1712 640 18
1314 707 21 1643 680 12 1595 676 39 1147 552 30 1001 578 34 885
491
[0161] TABLE-US-00039 TABLE 27 Comparison of fire performance of
various formulations containing IOH2 dispersed at least partially
on a nanometre scale, melamine cyanurate and optionally magnesium
hydroxide H7 Radiant Panel FAA 60 Second Extinguishment Vertical
burn time & Toxic Gas (0.75 mm) Burn length Smoke (FAA
(Extinguishment Formulation (average) Ds requirement) time seconds)
Nylon12 -- 21 Pass -- 22 -- 11.7 Pass -- 21 -- 10.4 Pass -- 20 --
7.8 Pass -- 19 -- 11.3 Pass -- 18 -- 11.4 Pass Fail (20) 17 -- 8.1
Pass Pass (9) 13 1 second 14.5 Pass Pass (0) 12.4 mm 12 -- 14.4
Pass Pass (0) 11 -- 7.5 Pass Fail (133) 39 -- 15 Pass Fail (58) 30
-- 14.5 Pass Pass (15) 34 2.5 second 11.3 Pass Pass (7) 15.0 mm
[0162] TABLE-US-00040 TABLE 28 Performance of materials,
incorporating IOH2 melamine cyanurate and Ng(OH).sub.2 with various
particle size and surface functionality Notched FAA 12 s Tensile
Tensile Impact Vertical burn MFI Modulus Strength Strength Ext.
Time (s) Formulation (g/min) (MPa) (MPa) (J/m.sup.2) (0.75 mm) 34
13.5 1480 40.4 5100 Pass (6) 41 11.5 1420 41 5000 Pass (6) 42 16.2
1470 40.2 5300 Pass (13) 44 12.4 1470 40.4 5300 Pass (14)
Example 15
The Following Example Illustrates the Mechanical and Vertical Burn
Performance (Table 29) of Nylon12 Formulations Prepared with the
Inorganic-Organic Hybrids Outlined in Examples 1, 2 & 4 and
Melamine Cyanurate
[0163] The results indicate superior fire performance of nylon12
formulations containing the intercalated and modified IOH (Examples
2 and 4) compared with that prepared with just melamine
hydrochloride modified IOH (Example 1). TABLE-US-00041 TABLE 29
Mechanical and Vertical Burn Performance 0.75 mm FAA Tensile
Tensile Notched 12 sec Strength Modulus Impact Vertical Burn
Formulation (MPa) (MPa) Strength J/m.sup.2 (Ext. time sec) 44 41.7
1490 5000 Fail (22) 45 39.5 1531 4100 Pass (12) 46 40.1 1580 4600
Pass (2) 47 39.2 1550 4100 Pass (5) 18 40.4 1590 4700 Fail (19) 12
39.3 1628 4000 Pass (3) Standard Deviation - Modulus <5%,
Strength <5%, Impact <10%
Example 16
The Following Example Illustrates the Performance of Nylon6 and
Nylon66 Formulations Incorporating IOH2 and Melamine Cyanurate
[0164] The results indicate that IOH2 at least partially dispersed
on a nanometre scale in conjunction with melamine cyanurate
provides excellent mechanical and vertical burn performance
relative to nylon6 and nylon66. TABLE-US-00042 TABLE 30 Mechanical
and Vertical Burn Performance Notched FAA 12 s Vertical Tensile
Tensile Impact burn Modulus Strength Strength Ext. Time (s)
Formulation (MPa) (MPa) (J/m.sup.2) (0.75 mm) Nylon6 2720 76 1900
Fail (61) 48 2970 73.5 2000 Pass (1) Nylon66 2890 83.5 1900 Fail
(65) 49 3500 67 1900 Pass (1)
Example 17
The Following Example shows the XRD of Nylon12 Formulations
Incorporating Modified and Intercalated Hectorite (Example 6)
Dispersed at Least Partially on a Nanometre Scale (FIG. 5) and
Melamine Cyanurate and the Formulations Vertical Burn Performance
(Table 31)
[0165] The XRD results indicate that hectorite is modified owing to
its larger intergallery spacing compared with the starting
material. Nylon12 incorporating IOH5 at least partially dispersed
on a nanometre scale (FIG. 5) and melamine cyanurate show excellent
fire performance. TABLE-US-00043 TABLE 31 Vertical Burn Performance
FAA 12 s Vertical burn, Ext. Time Formulation (s)(0.75 mm) Nylon12
Fail (68) 50 Pass (2)
Example 18
This Example Shows the Rheology (Table 32) and Mechanical and
Vertical Burn Performance (Table 33) of Formulations Incorporating
IOH2, Conventional Flame Retardant and Minor Processing
Additives
[0166] This example illustrates that reductions in viscosity across
a range of shear rates of the formulations incorporating nylon12,
IOH2 and conventional flame retardants through the addition of
(additional) minor processing additives during processing. This
reduction in viscosity is possible with out a significant reduction
in mechanical performance and generally without compromising fire
performance particularly under the stringent conditions required to
fire retard thin materials to meet performance standards outlined
by various regulatory bodies. TABLE-US-00044 TABLE 32 Rheology of
formulations at different shear rates and corresponding MFI data
Shear rate 10.sup.-2 10.sup.-1 10.sup.0 10.sup.1 MFI Formulation
Viscosity (Pas) g/min Nylon12 223 169 106 108 35 13 13100 1750 300
124 29 34 719 624 560 502 13 51 4800 1040 226 128 34 52 1920 6590
1560 95 39 53 1100 865 168 95 39 54 554 865 162 95 41 55 98300 1930
335 143 33 56 13500 1870 284 106 31
[0167] TABLE-US-00045 TABLE 33 Mechanical and Vertical Burn
Performance Notched 0.75 mm FAA 12 sec Tensile Tensile Impact
Vertical Burn Modulus Strength Strength (Extinguishment Formulation
(MPa) (MPa) (J/m.sup.2) time (s)) Nylon12 1100 36 4600 Fail (62) 13
1349 38.9 4700 Pass (2) 34 1480 40.4 5100 Pass (6) 51 1215 35.8
3500 Pass (3) 52 1165 35.5 3500 Pass (2) 53 1233 36.4 3500 Pass
(13) 54 1176 35.3 3300 Fail (25) 55 1168 33.3 3300 Pass (8) 56 1241
35 3700 Pass (10)
Example 19
This Example Provides the Mechanical and Fire Performance (Table
34) of Nylon12 Formulations Incorporating IOH2, Conventional Flame
Retardants and Minor Component of Stabilizer
[0168] The results indicate that the mechanical and vertical burn
performance of formulations containing nylon12, IOH2 conventional
flame retardant is not significantly reduced by addition of
additional stabilizer to the formulation during compounding.
TABLE-US-00046 TABLE 34 Mechanical and Vertical Burn Performance
Notched 0.75 mm FAA 12 sec Tensile Tensile Impact Vertical Burn
Modulus Strength Strength (Extinguishment Formulation (MPa) (MPa)
J/m.sup.2 time (s)) Nylon12 1100 36 4600 Fail (62) 13 1349 38.9
4700 Pass (2) 57 1394 39.1 4800 Pass (4)
Example 20
This Example Shows that Formulations Incorporating IOH's May not
Only be Fabricated into Materials, Components and Parts of
Components by Processes Such as Extrusion, Injection Moulding,
Compression Moulding and Alike But Also by Low Shear Processes Such
as Rotational Moulding (FIG. 6) and Selective Laser Sintering.
[0169] FIG. 6 provides examples of components manufactured by
rotational moulding employing formulations incorporating IOH2,
melamine cyanurate optionally magnesium hydroxide and other
additives such as but not limited to formulation 13 and 34. The
examples illustrate that such formulations show suitable
thermal/oxidative stability and melt rheology for manufacturing
components under low shear and thermally demanding
environments.
[0170] It will be appreciated by persons skilled in the art that
numerous variations and/or modifications may be made to the
invention as shown in the specific embodiments without departing
from the spirit or scope of the invention as broadly described. The
present embodiments are, therefore, to be considered in all
respects as illustrative and not restrictive.
* * * * *