초록
▼
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...
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.
대표
청구항
▼
1. A flame retardant material, comprising: a polymer, wherein the polymer is one or more materials selected from the group consisting of: polyesters, polycarbonates, polyetherimides, polyamides, polyimides, polysulfones, acetal polymers, polyether ketones, acrylic polymers, halogenated polymers, polyphenylenes, polyphenylene ethers, polyphenylene sulfide, ABS polymers, polystyrene, melamine formaldehyde polymers, urea formaldehyde polymers, epoxy polymers, and their copolymers; anda flame retardant filler comprising a mesoporous amorphous magnesium carbo...
1. A flame retardant material, comprising: a polymer, wherein the polymer is one or more materials selected from the group consisting of: polyesters, polycarbonates, polyetherimides, polyamides, polyimides, polysulfones, acetal polymers, polyether ketones, acrylic polymers, halogenated polymers, polyphenylenes, polyphenylene ethers, polyphenylene sulfide, ABS polymers, polystyrene, melamine formaldehyde polymers, urea formaldehyde polymers, epoxy polymers, and their copolymers; anda flame retardant filler comprising a mesoporous amorphous magnesium carbonate selectively hydrated with at least 0.11 grams water/gram filler. 2. The flame retardant material of claim 1, wherein the flame retardant filler comprises particles having dimension between about 0.010 microns and about 25 microns. 3. The flame retardant material of claim 1, wherein the flame retardant filler is present at a concentration between about 5 weight percent and about 50 weight percent of the flame retardant material. 4. The flame retardant material of claim 1, further comprising a second filler selected from the group consisting of carbonate minerals, hydroxide minerals, and flame retardant synergists. 5. The flame retardant material of claim 4, wherein the second filler is selected from the group consisting of magnesium carbonate, hydromagnesite, huntite, aluminum trihydroxide, magnesium hydroxide, brucite, boehmite, bauxite, borates, clays, organoclays, and oxides of antimony. 6. The flame retardant material of claim 1, wherein the flame retardant filler has a pore size distribution between about 2 nanometers and about 50 nanometers, and an average BET pore size between about 10 nanometers and about 20 nanometers. 7. The flame retardant material of claim 1, wherein the flame retardant filler has a BET specific surface area between about 60 square meters per gram and about 1500 square meters per gram. 8. The flame retardant material of claim 1, wherein the flame retardant filler is selectively hydrated with at least about 0.22 gram water/gram filler. 9. The flame retardant material of claim 1, wherein the flame retardant filler does not degrade from one or more hydration or dehydration cycles. 10. The flame retardant material of claim 1, wherein the flame retardant filler is a hydrated mesoporous amorphous magnesium carbonate. 11. The flame retardant material of claim 1, wherein the flame retardant filler is saturated with water. 12. The flame retardant material of claim 1, wherein the flame retardant filler has pores with dimension between about 2 nanometers and about 50 nanometers, and a surface area of about 800 m2/gram. 13. The flame retardant material of claim 1, wherein the flame retardant filler is treated with a process aid. 14. The flame retardant material of claim 13, wherein the process aid is chemically bonded to the filler surface. 15. The flame retardant material of claim 13, wherein the process aid comprises a coupling agent. 16. The flame retardant material of claim 15, wherein the amount of coupling agent is between about 0.01% and about 10% by weight of the filler. 17. The flame retardant material of claim 15, wherein the coupling agent is selected from the group consisting of silanes, titanates, zirconates, aluminates, unsaturated carboxylic acids, anhydrides, esters, and phosphates. 18. The flame retardant material of claim 1, wherein the flame retardant material decomposes at a temperature of between about 125° C. and about 450° C. 19. The flame retardant material of claim 1, wherein the flame retardant material has a controllable water-effusion temperature of between about 125° C. and about 300° C. 20. The flame retardant material of claim 1, wherein the filler median particle diameter is between about 1 and about 10 microns. 21. The flame retardant material of claim 1, wherein the polymer is modified with a chemical functional species that binds or interacts with the filler surface. 22. The flame retardant material of claim 1, wherein the filler is treated with an additive selected from the group consisting of lubricants, nucleating agents, extension oils, organic and inorganic pigments, anti-oxidants and UV-protectors, heat stabilizers, and plasticizers. 23. The flame retardant material of claim 1, further comprises a polyolefin.