Fire resistant material

Patent metadata

Field	Value
Publication number	US-9745515-B2
Application number	US-201113089658-A
Country	US
Kind code	B2
Filing date	Apr 19, 2011
Priority date	Oct 31, 2002
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

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.

First claim

The invention claimed is:

1. A formulation which comprises either:
(A) (a) an inorganic-organic hybrid (IOH) which comprises:
(i) an expandable or swellable layered inorganic component, which is a naturally occurring or synthetic analogue of a phyllosilicate having a platelet thickness less than 5 nanometers and an aspect ratio greater than 10:1; and
(ii) an organic component including at least one ionic organic component and one or more neutral organic components which are intercalated between the layer(s) of the inorganic component to provide an intergallery spacing expanded to greater than 1.27 nm and not more than 1.84 nm, in which the neutral organic component is a neutral derivative of a triazine based species,
the ionic or neutral organic components 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
(b) a polyamide based matrix; or

(B) (a) a fire resistant formulation which comprises the IOH defined as component (a) under (A) above; and one or more flame retardants; and
(b) a polyamide based matrix,
wherein the IOH for both (A) and (B) is in the form of solid particles.

2. A formulation according to claim 1 , 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.

3. A formulation according to claim 1 , in which the polyamide based matrix is selected from Nylon12, Nylon6 and Nylon66 and co-polymers, alloys or blends thereof.

4. A formulation according to claim 1 , which further comprises one or more additives.

5. A formulation according to claim 2 , 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.

6. A formulation according to claim 5 , in which the polymeric stabiliser is a UV, light or thermal stabilizer.

7. A formulation according to claim 5 , 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.

8. A formulation according to claim 1 , 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.

9. A formulation according to claim 4 , 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.

10. A formulation according to claim 4 , 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 less than about 4% w/w.

11. A formulation according to claim 4 , 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.

12. A formulation according to claim 1 , in which the inorganic component is rendered positively or negatively charged due to isomorphic substitution of elements within the layers.

13. A formulation according to claim 1 , in which the naturally occurring or synthetic analogue of a phyllosilicate is a smectite clay.

14. A formulation which comprises either:
(A) (a) an inorganic-organic hybrid (IOH) which comprises:
(i) an expandable or swellable layered inorganic component, which is a naturally occurring or synthetic analogue of a phyllosilicate having a platelet thickness less than 5 nanometers and an aspect ratio greater than 10:1; and
(ii) an organic component including at least one ionic organic component and one or more neutral organic components which are intercalated between the layer(s) of the inorganic component, in which the neutral organic component is a neutral derivative of a triazine based species,
the ionic or neutral organic components 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
(b) a polyamide based matrix; or

(B) (a) a fire resistant formulation which comprises the IOH defined as component (a) under (A) above; and one or more flame retardants; and
(b) a polyamide based matrix,

wherein the IOH for both (A) and (B) is in the form of solid particles, and wherein the IOH is selected from the group consisting of melamine and melamine hydrocholoride modified montmorillonite, melamine and melamine cyanurate hydrochloride modified montmorillonite, melamine and trimethyl cetylammonium chloride modified montmorillonite, and melamine and melamine hydrochloride modified synthetic hectorite.

15. A formulation according to claim 13 , 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.

16. A formulation according to claim 1 , in which the naturally occurring phyllosilicate is selected from bentonite, montmorillonite and hectorite.

17. A formulation according to claim 1 , in which the aspect ratio is greater than about 50:1.

18. A formulation according to claim 1 , in which the aspect ratio is greater than about 100:1.

19. A formulation according to claim 1 , in which the layers of the inorganic component have an intergallery distance greater than 1.3 nanometers.

20. A formulation according to claim 1 , in which the inorganic component includes interlayer or exchangeable metal cations.

21. A formulation according to claim 20 , in which the metal cation is selected from an alkali metal and alkali earth metal.

22. A formulation according to claim 21 , in which the alkali or alkali earth metal is selected from Na + , K + , Mg 2+ and Ca 2+ .

23. A formulation according to claim 20 , in which the cation exchange capacity of the inorganic component is less than about 400 milli-equivalents per 100 grams.

24. A formulation according to claim 1 , in which the ionic organic component was exchanged with exchangeable metal ions of the inorganic component.

25. A formulation according to claim 1 , in which the ionic organic component contains onium ion(s).

26. A formulation according to claim 25 , in which the ionic organic component containing onium ion(s) is an ammon

Assignees

• Bateman Stuart Arthur
• Partlett Matthew Jon
• Wu Dong Yang
• Commw Scient Ind Res Org
• Boeing Co

Inventors

• Bateman Stuart Arthur
• Partlett Matthew Jon
• Wu Dong Yang

Classifications

• C01B33/44

  Products obtained from layered base-exchange silicates by ion-exchange with organic compounds such as ammonium, phosphonium or sulfonium compounds or by intercalation of organic compounds, e.g. organoclay material · CPC title

• C09K21/06 Primary

  Organic materials · CPC title

• C08K2003/343

  Peroxyhydrates, peroxyacids or salts thereof · CPC title

• C08K5/0066

  Flame-proofing or flame-retarding additives · CPC title

• Y10S57/904

  Flame retardant · CPC title