Flame retardant materials

Patent metadata

Field	Value
Publication number	US-12227663-B2
Application number	US-202017786141-A
Country	US
Kind code	B2
Filing date	Dec 18, 2020
Priority date	Dec 18, 2019
Publication date	Feb 18, 2025
Grant date	Feb 18, 2025

Abstract

The invention provides a flame retardant material comprising a substrate, an optionally corona-treated coating on the substrate, the coating comprising a polyolefin composition comprising a) an ethylene based plastomer with a density in the range of 0.857 to 0.915 g/cm 3 and an MFR 2 in the range 0.5-30 g/10 min; b) a propylene based plastomer with a density in the range of 0.860 to 0.910 g/cm 3 and an MFR 2 in the range 0.01-30 g/10 min; and c) a flame retardant, a primer layer on top of the coating and a lacquer topcoat.

First claim

The invention claimed is:

1. A flame retardant material comprising:
(a) a substrate;
(b) a coating on the substrate, the coating comprising a flame retardant polyolefin composition (X) comprising:
(i) an ethylene based plastomer with a density in the range of 0.857 to 0.915 g/cm 3 and an MFR 2 (190° C.; 2.16 kg) in the range 0.5-30 g/10 min;
(ii) a propylene based plastomer with a density in the range of 0.850 to 0.910 g/cm 3 and an MFR 2 (230° C./2.16 kg) in the range 0.01-30 g/10 min; and
(iii) a flame retardant (FR);

(c) a primer layer on top of the coating; and
(d) a lacquer topcoat on top of the primer layer.

2. The flame retardant material of claim 1 , wherein the flame retardant polyolefin composition (X) comprises:
a flame retardant (FR);
A) 5 to 35 wt. %, based on the overall weight of the flame retardant polyolefin composition, of a recycled polyolefin fabric substrate; wherein said recycled polyolefin fabric substrate is coated with a polymer composition (p1) comprising the following components:
a1) an ethylene based plastomer with a density in the range of 0.857 to 0.915 g/cm 3 and a MFR 2 (190° C., 2.16 kg) in the range of 0.5 to 30 g/10 min; and
a2) a propylene based plastomer in the range of 0.850 to 0.910 g/cm 3 and a MFR 2 (230° C., 2.16 kg) in the range of 0.01 to 30 g/10 min;

B) 65 to 95 wt. % based on the overall weight of the flame retardant polyolefin composition of a homopolypropylene or a recycled polymer blend comprising b1) polypropylene and b2) polyethylene, wherein the weight ratio of b1) to b2) is from 3:7 to 12:1; and
C) optionally one or more additives;
with the proviso that the amounts of the flame retardant (FR) and components A), B), and C) (when present) add up to 100 wt. %.

3. The flame retardant material of claim 1 , comprising:
20 to 90 wt % of the ethylene based plastomer (i), relative to the total weight of the polyolefin composition (X) as a whole,
5 to 45 wt % of the propylene based plastomer (ii), relative to the total weight of the polyolefin composition (X) as a whole,
or a combination thereof.

4. The flame retardant material of claim 1 , wherein the polyolefin composition (X) further comprises a high melt flow rate propylene based plastomer.

5. The flame retardant material of claim 1 , wherein:
the ethylene based plastomer (i) is a copolymer of ethylene and at least one C3-C10 alpha-olefin,
the propylene based plastomer (ii), is a copolymer of propylene and ethylene or a C4-C10 alpha-olefin,
or a combination thereof.

6. The flame retardant material of claim 1 , wherein the flame retardant is present in an amount of 1.5 to 30 wt %, relative to the total weight of the polyolefin composition (X) as a whole.

7. The flame retardant material of claim 1 , wherein the flame retardant comprises an ammonium polyphosphate.

8. The flame retardant material of claim 1 , wherein the primer is an acrylic-modified polyethylene.

9. The flame retardant material of claim 1 , wherein the lacquer topcoat comprises a polyurethane or a fluoropolymer.

10. The flame retardant material of claim 1 , wherein the substrate is a fabric substrate.

11. The flame retardant material of claim 1 , wherein the substrate is a polypropylene fabric.

12. An article comprising the flame retardant material of claim 1 , wherein the article is selected from the group consisting of office furniture, vehicle interiors, seat cushions, back rest cushions, pillows, upholstered furniture, bed mattresses, wall coverings, shoes, sports bags, inlay of ski boots, sports equipment, carpets, rubber boats, PVC swimming pools, life vests, handbags, purses, table coverings, table mats, stationary, saddlebags, and tool bags.

13. The flame retardant material of claim 1 , wherein the coating is corona treated.

14. The flame retardant material of claim 1 , wherein the flame retardant polyolefin composition (X) comprises:
a flame retardant (FR);
A1) 5 to 35 wt. %, based on the overall weight of the flame retardant polyolefin composition, of a recycled polyolefin fabric substrate; wherein said fabric substrate is coated with a polymer composition (p2) comprising the following components:
a11) an ethylene based plastomer with a density in the range of 0.857 to 0.915 g/cm 3 and a MFR 2 (190° C., 2.16 kg) in the range of 0.5 to 30 g/10 min; and
a12) a propylene based plastomer in the range of 0.850 to 0.910 g/cm 3 and a MFR 2 (230° C., 2.16 kg) in the range of 0.01 to 30 g/10 min;

B1) 65 to 95 wt. % based on the overall weight of the flame retardant polyolefin composition of a virgin polyolefin composition (p3) comprising the following components:
b11) an ethylene based plastomer with a density in the range of 0.857 to 0.915 g/cm 3 and a MFR 2 (190° C., 2.16 kg) in the range of 0.5 to 30 g/10 min; and
b12) a propylene based plastomer with a density in the range of 0.850 to 0.910 g/cm 3 and a MFR 2 (230° C., 2.16 kg) in the range of 0.01 to 30 g/10 min; and

C1) optionally one or more additives;
with the proviso that the amounts of the flame retardant (FR) and components A1), B1), and C1) (when present) add up to 100 wt. %.

15. The flame retardant material of claim 1 , wherein the flame retardant comprises an ammonium polyphosphate in combination with a silane functionalized ethylene copolymer.

16. The flame retardant composition material of claim 15 , wherein the silane functionalized ethylene copolymer comprises a copolymer of ethylene with a methylacrylate comonomer and a vinyl trimethoxysilane comonomer.

17. A process for producing the flame retardant material of claim 1 , the process comprising:
(A) providing a coated substrate, the coated substrate being the substrate coated with the coating comprising the flame retardant polyolefin composition (X);
(B) applying the primer layer to the coated substrate of step (A);
(C) applying the lacquer topcoat on top of the primer layer; and
(D) optionally embossing the resulting flame retardant material.

18. The process of claim 17 , wherein the coated substrate is prepared by applying the coating of the polyolefin composition (X) to the substrate.

19. The process of claim 17 , further comprising corona treating the coated substrate before application of the primer layer.

Assignees

• Borealis Ag

Inventors

• Pastorini Mirela Tury
• Defoer Johan
• Ek Carl-Gustaf
• Lewis Gavin

Classifications

• D10B2507/00

  Sport; Military · CPC title

• D10B2505/10

  Packaging, e.g. bags · CPC title

• D10B2505/08

  Upholstery, mattresses · CPC title

• D10B2503/04

  Floor or wall coverings; Carpets · CPC title

• D06N2211/103

  Gloves · CPC title