Embodiments of the disclosure generally provide flame retardant compositions and methods comprising organic polymers, mineral fillers, high surface area mineral fillers and process aids. Compositions of the disclosure additionally are comprised of high surface area hydrated metal carbonate fillers,
Embodiments of the disclosure generally provide flame retardant compositions and methods comprising organic polymers, mineral fillers, high surface area mineral fillers and process aids. Compositions of the disclosure additionally are comprised of high surface area hydrated metal carbonate fillers, including the mesoporous amorphous magnesium carbonate filler Upsalite. The filler's porous structure and high surface area provides high water capacity, enhanced physical and chemical interaction with a polymer in composite, lower by weight loadings of filler in a composite, as well as effective flame retardancy.
대표청구항▼
1. A method of producing a flame retardant object, comprising: milling a flame retardant filler comprising a mesoporous amorphous magnesium carbonate to a particle size between about 0.010 microns and about 25 microns;hydrating the filler in a humid environment to a level of at least about 0.11 gram
1. A method of producing a flame retardant object, comprising: milling a flame retardant filler comprising a mesoporous amorphous magnesium carbonate to a particle size between about 0.010 microns and about 25 microns;hydrating the filler in a humid environment to a level of at least about 0.11 grams water/gram of filler;compounding the hydrated filler with a polymer, to form a flame retardant composite wherein the weight percent of the filler in the flame retardant composite is between about 5 percent and about 50 percent by weight of the flame retardant composite; andforming an object from a flame retardant composite. 2. The method of claim 1, wherein the filler comprises Upsalite. 3. The method of claim 1, wherein the polymer comprises a material selected from the group consisting of: polyolefins, polyesters, polycarbonates, polyetherimides, polyamides, polyimides, polysulfones, acetals, polyether ketones, acrylics, nylons, halogenated polymers, polyphenylenes, polyphenylene ethers, polyphenylene sulfide, ABS combinations, polystyrene, melamine formaldehydes, urea formaldehydes, epoxies, and their copolymers. 4. The method of claim 1, wherein the filler is treated with a coupling agent selected from the group comprising silanes, titanates, zirconates, aluminates, carboxylic acids, unsaturated carboxylic acids, anhydrides, esters, and phosphates. 5. The method of claim 1, wherein the coupling agent is chemically bound to the filler surfaces. 6. The method of claim 1, wherein the hydrated filler has a controllable water-effusion temperature of between about 250° C. and about 300° C. 7. The method of claim 1, wherein the hydrated filler is water saturated. 8. The method of claim 1, wherein the polymer or polymer-filler mixture is treated with a coupling agent selected from the group comprising silanes, titanates, zirconates, aluminates, carboxylic acids, unsaturated carboxylic acids, anhydrides, esters, and phosphates. 9. The method of claim 1, wherein a second filler is mixed with the polymer, and the second filler is selected from the group comprising carbonate minerals, magnesium carbonate, hydromagnesite, huntite, hydroxide minerals, aluminum trihydroxide, magnesium hydroxide, brucite, boehmite, bauxite, borates, flame retardant synergists, clays, organoclays, and oxides of antimony. 10. The method of claim 1, wherein the polymer is in a molten state. 11. The method of claim 1, wherein the polymer is dissolved in a solvent and mixed with the filler. 12. The method of claim 1, wherein the polymer is modified with a chemical functional species that binds or interacts with the filler surface. 13. The method of claim 12, wherein the chemical functional species is attached to the polymer by means of a radical reaction. 14. The method of claim 1, wherein a coupling agent is added to the mixture in combination with a radical initiator so as to graft the coupling agent directly onto the polymer material. 15. The method of claim 1, wherein the filler is treated with an additive selected from the group comprising lubricants, nucleating agents, extension oils, organic and inorganic pigments, anti-oxidants and UV-protectors, heat stabilizers, and plasticizers. 16. The method of claim 1, wherein in situ polymerization of monomers and oligomers is in the presence of the filler. 17. The method of claim 1, wherein the coupling agent to be added to the filler is between about 0.01% and about 10% by weight. 18. The method of claim 1, wherein the filler median particle diameter is between about 1 and about 10 microns. 19. The method of claim 1, wherein the flame retardant material decomposes at a temperature of between about 125° C. and about 400° C. 20. The method of claim 1, wherein the filler is hydrated to a level of at least about 0.22 grams water/gram of filler.
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이 특허에 인용된 특허 (5)
Legare David J. (11 Bonnie Ave. New Hartford NY 13413), Cellular ceramic and foam materials.
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