Fire resistant material
09745515 · 2017-08-29
Assignee
- Commonwealth Scientific And Industrial Research Organisation (Campbell, ACT, AU)
- The Boeing Company (Seattle, WA)
Inventors
- Stuart Arthur Bateman (Victoria, AU)
- Matthew Jon Partlett (New South Wales, AU)
- Dong Yang Wu (Victoria, AU)
Cpc classification
International classification
C01B33/44
CHEMISTRY; METALLURGY
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.
Claims
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.sup.+, K.sup.+, Mg.sup.2+ and Ca.sup.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 ammonium, phosphonium or sulfonium derivative of an aliphatic, aromatic or aryl-aliphatic amine, phosphine or sulfide.
27. A formulation according to claim 1, in which the ionic organic component is an ionic derivative of a nitrogen based molecule.
28. A formulation according to claim 27, in which the nitrogen based molecule is a triazine based species.
29. A formulation according to claim 1, in which the triazine based species is selected from melamine, triphenyl melamine, melam (1,3,5-triazine-2,4,6-triaminen-(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, low molecular weight polymers with triazine and phosphazine repeat units and isocyanuric acid and salts or derivatives thereof.
30. A formulation according to claim 29, 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.
31. A formulation according to claim 27, in which the organic component is a derivative of phosphoric acid or boric acid.
32. A formulation according to claim 31, in which the derivative of phosphoric acid or boric acid is selected from ammonia polyphosphate, melamine polyphosphate and melamine phosphate ammonium borate.
33. A formulation 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.
34. A formulation according to claim 33, in which the other ionic compound is an amphiphilic molecule that incorporates a hydrophilic ionic group along with hydrophobic alkyl or aromatic moieties.
35. A formulation according to claim 1, in which the IOH further comprises one or more coupling reagents.
36. A formulation according to claim 35, in which the coupling reagent is selected from an organically functionalised silane, zirconate and titanate.
37. A formulation according to claim 36, 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.
38. A formulation according to claim 1, 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.
39. A formulation according to claim 38, in which the phosphorus derivatives are selected from melamine phosphate, dimelamine phosphate, melamine polyphosphate, ammonia phosphate, ammonia polyphosphate, pentaerythritol phosphate, melamine phosphite and triphenyl phosphine.
40. A formulation according to claim 38, 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.
41. A formulation according to claim 38, in which the molecules containing borate functional groups are selected from ammonia borate and zinc borate.
42. A formulation according to claim 38, in which the molecules containing two or more alcohol groups are selected from pentaerythritol, polyethylene alcohol, polyglycols and carbohydrates.
43. A formulation according to claim 38, in which the molecules which endothermically release noncombustible decomposition gases are selected from magnesium hydroxide and aluminum hydroxide.
44. A method for the preparation of the formulation of claim 1 which comprises mixing the IOH and the polyamide based matrix or constituents thereof in one or more steps.
45. A method according to claim 44, in which mixing is achieved using melt, solution or powder processing.
46. A method according to claim 44, 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.
47. A method for the preparation of the formulation of claim 1 which comprises dispersing the IOH or constituents thereof into the polyamide based matrix in one or more steps.
48. A method according to claim 47, in which at least some of the components are ground prior to mixing.
49. A method according to claim 48, in which the components are ground to a particle size less than 200 microns.
50. A method according to claim 47, in which dispersion is achieved using melt, solution or powder processing.
51. A method according to claim 47, in which dispersion is achieved using melt processing in a single or twin screw extruder, batch mixer or continuous compounder.
52. A method according to claim 51, in which the melt processing is conducted in a twin screw extruder.
53. A method according to claim 47, in which the dispersion occurs at a sufficient shear rate, shear stress and resistance time to disperse the IOH at least partially on a nanometer scale.
54. A fire resistant article or parts thereof which is composed wholly or partly of the fire resistant formulation of claim 1 made from the formulation of claim 1.
55. A fire resistant article or parts thereof as defined in claim 54, which is a hollow article or sheet.
56. A fire resistant article or parts thereof as defined in claim 54, which is selected from pipes, ducts, fabric, carpet, wires, fibers, Environmental control systems, stowage bin hinge covers, cable trays, ECS duct spuds, latches, brackets, passenger surface units and thermoplastic laminate sheet.
57. A fire resistant fiber, fabric, carpet or parts thereof which is composed wholly or partly of the fire resistant formulation made from the formulation of claim 1.
58. A method of preparing the fire resistant article or parts thereof defined in claim 55, which comprises molding or forming the fire resistant formulation or constituents thereof made from the formulation of claim 1.
59. A method according to claim 58, in which the molding or forming is carried out using extrusion, injection molding, compression molding, rotational molding, blow molding, sintering, thermoforming, calending or combinations thereof.
60. A method of producing a polyamide fire resistant formulation, the process comprising extruding the formulation of claim 1.
61. A fire resistant formulation comprising: an inorganic-organic hybrid which comprises: 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 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, 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; wherein the neutral organic component is melamine and the ionic organic component is selected from at least one of melamine hydrochloride, melamine cyanurate hydrochloride and trimethylcetylammonium chloride.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the examples, reference will be made to the accompanying drawings in which:
(2)
(3)
(4)
(5)
(6)
(7)
EXAMPLES
(8) The invention will now be described with reference to the following non-limiting examples.
(9) General Conditions & Reagents
(10) Tables 1, 2 and 3 Outline General Reagents, Conditions & Procedures associated with the examples.
(11) 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
(12) TABLE-US-00002 TABLE 2 Processing Equipment and Conditions Equipment Type Twin Berstorff ZE 25 mm modular co-rotating twin screw screw extruder coupled to a Haake Rheocord motor drive and extruder torque cell for rheology measurement L:D ratio = 36:1 Screw and barrel configuration presented in FIG. 1, Screw speed 300 rpm Feed rate ~1.2 Kg/hour Residence time average 2 min Flat 200° C. temperature profile from throat to die (nylon12) Flat 250° C. temperature profile from throat to die (nylon6) Flat 275° C. temperature profile from throat to die (nylon66) Batch Haake R3000 batch mixer connected to torque rheological Mixer load cell, pneumatic ram, roller rotors Rotor speed - 5 min 60 rpm, 10 min 120 rpm Temperature 190° C. Injection Battenfeld 80 ton BA 800 CDC injection moulding machine Moulding Temperature profile: Nylon 12 Zone 1 2 3 Nozzle Die Temp (° C.) 215 220 225 225 70° C. Nylon 6 Zone 1 2 3 Nozzle Die Temp (° C.) 230 230 250 260 90° C. Nylon 66 Zone 1 2 3 Nozzle Die Temp (° C.) 260 260 280 290 90° 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 Com- Assett 2.5 MPa pneumatic press, 45 cm platens, pression heating (400° C.) and cooling Moulding Moulding platen temperature 220° C. nylon12 Moulding platen temperature 260° C. nylon6 Moulding platen temperature 290° C. nylon66
(13) TABLE-US-00003 TABLE 3 Characterization Techniques, Conditions and Sample Preparations Equipment Type X-ray diffraction Phillips PW 1729, CuK.sub.α1 source λ = 0.154 nm (XRD) Powders were ground to a particle size of less than 100 micron, Plastics were compression moulded (210° 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° C. and 20° 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° 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° C./min Analysis (TGA) Powders were ground to a particle size of less than 100 micron Plastics were compression moulded (210° 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 × 100 × 6 mm) were conditions for 7 days at 23° 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 × 12.3 × 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 × 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 × 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° 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° 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
(14) Preparation of melamine hydrochloride modified montmorillonite (IOH1)
(15) Montmorillonite exchanged Na.sup.+ (Cation Exchange Capacity (CEC)=92 meg/100 g) was suspended in 80° 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° C.) The resultant granular organically modified clay was ground to a particle size of less than 50 micron and then further dried at 75° C. prior to processing or analysis.
(16) TABLE-US-00004 XRD (CuK.sub.α1 source λ = 0.154 nm) Melamine•HCl modified Cation Na.sup.+ Montmorillonite XRD d.sub.001 1.10 nm 1.27 nm
(17) 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 in region during ion exchange.
Example 2a
(18) Preparation of melamine hydrochloride modified montmorillonite in the presence of melamine (IOH2)
(19) Montmorillonite exchanged Na.sup.+ (Cation Exchange Capacity (CEC)=92 meq/100 g) was suspended in 80° 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° C.) The resultant granular organically modified clay was ground to a particle size of less than 50 micron and then further dried at 75° C. prior to processing or analysis.
(20) TABLE-US-00005 XRD (CuK.sub.α1 source λ = 0.154 nm) Melamine and Melamine•HCl modified Cation Na.sup.+ montmorillonite XRD d.sub.001 1.10 nm 1.39 nm
(21) 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
(22) Preparation of melamine hydrochloride modified montmorillonite in the presence of melamine (IOH2)
(23) 3.0 Kg of sodium montmorillonite was dispersed into 200 L de-ionized water at 60° 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 (35 L) containing 1.39 Kg melamine and 0.92 L HCl (9.65M) at 85° 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° C. Following filtration of the suspension the collected modified clay was re-dispersed into de-ionized water (150 L) and allowed to stir for 1 hour at 60° C. before an aqueous solution (10 L) containing 0.385 Kg melamine and 0.26 L HCl (9.65M) at approx 85° 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 (150 L) and stirred for a further 1 hour at 60° C. prior to filtration, drying and grinding of the modified clay to a particle size less than 50 micron.
(24) TABLE-US-00006 XRD (CuK.sub.α1 source λ = 0.154 nm) Melamine and Melamine•HCl modified Cation Na.sup.+ Montmorillonite XRD d.sub.001 1.10 nm 1.40 nm
(25) 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/autrapment of the neutral melamine with the clay during ion exchange.
Example 2c
(26) Preparation of melamine hydrochloride modified montmorillonite in the presence of melamine (IOH2)
(27) 15.0 Kg of montmorillonite was dispersed into 200 L de-ionized water at 60° 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 (50 L) containing 2.78 Kg melamine and 1.84 L HCl (9.65 M) at 85° 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° C. Following filtration of the suspension the collected modified clay was re-dispersed into de-ionized water (150 L) and allowed to stir for 1 hour at 60° C. before an aqueous solution (25 L) containing 1.925 Kg melamine and 1.3 L HCl (9.65M) at approx 85° 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 (200 L) and stirred for a further hour at 60° C. prior to filtration, drying and grinding of the modified clay to a particle size less than 50 micron.
(28) TABLE-US-00007 XRD (CuK.sub.α1 source λ = 0.154 nm) Melamine and Melamine•HCl modified Cation Na.sup.+ Montmorillonite XRD d.sub.001 1.10 nm 1.40 nm
(29) 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
(30) Preparation of melamine cyanurate hydrochloride modified montmorillonite (IOH3)
(31) Na.sup.+ exchanged montmorillonite (Cation Exchange Capacity (CEC)=92 meq/100 g) was suspended in 95° 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 (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° 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° C. prior to processing or analysis.
(32) TABLE-US-00008 XRD (CuK.sub.α1 source λ = 0.154 nm) Melamine cyanurate•HCl modified Cation Na.sup.+ montmorillonite XRD d.sub.001 1.10 nm 1.42 nm
(33) 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
(34) Preparation of melamine and melamine cyanurate modified montmorillonite in presence of melamine and melamine cyanurate (IOH4)
(35) Montmorillonite exchanged Na.sup.+ (Cation Exchange Capacity (CEC)=92 meq/100 g) was suspended in 95° 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° 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° C. prior to processing or analysis.
(36) TABLE-US-00009 XRD (CuK.sub.α1 source λ = 0.154 nm) Melamine and Melamine cyanurate•HCl Cation Na.sup.+ modified montmorillonite XRD 1.10 nm 1.53 nm d.sub.001
(37) 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
(38) Preparation of melamine and trimethyl cetylammonium and melamine hydrochloride modified montmorillonite (IOH5)
(39) Montmorillonite exchanged Na.sup.+ (Cation Exchange Capacity (CEC)=92 meq/100 g) was suspended in 90° 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° 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° C. prior to processing or analysis.
(40) TABLE-US-00010 XRD (CuK.sub.α1 source λ = 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
(41) 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
(42) Preparation of melamine and melamine hydrochloride modified synthetic hetorite, laponite (IOH6)
(43) 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.
(44) TABLE-US-00011 XRD (CuK.sub.α1 source λ = 0.154 nm) Cation Na.sup.+/Li.sup.+ Melamine and Melamine•HCl Modified Hectorite XRD d.sub.001 1.20 nm 1.33 nm
(45) 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.
(46) Melt Dispersion of Components and Formulation of Fire Resistant Materials Examples 7-20
(47) 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.
(48) The formulation constituents employed in Examples 7 to 20 are provided in Tables 4a to 4e.
(49) TABLE-US-00012 TABLE 4a Formulations used in Examples 7 to 20 IOH2 Formu- Cloisite Cloisite Cloisite (Example Melamine lation Nylon12 Na.sup.+ 30B 93A 2) 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
(50) TABLE-US-00013 TABLE 4b Formulations used in Examples 7 to 20 Magnesium Melamine Ammonia Penta- Penta- Formu- IOH2 Melamine Hydroxide Melamine poly Melamine poly erythritol erythritol lation 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
(51) TABLE-US-00014 TABLE 4c Formulations used in Examples 7 to 20 IOH2 Melamine Magnesium Magnesium Magnesium Magnesium Formulation Nylon12 (Example 2) cyanurate hydroxide (H7) hydroxide (H10) hydroxide (H5iv) hydroxide (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
(52) 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
(53) 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
(54) Processing rheology (Table 5), XRD & TEM (
(55) 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 nylon 12(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, ASTM, FAA and the like. As such these materials do not meet such performance standards
(56) 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
(57) 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
(58) TABLE-US-00019 TABLE 7 Fire Testing Cone Results Peak Heat Mass Loss CO CO.sub.2 SEA Rel.sup.d Rate Prod.sup.n 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
(59) 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
(60) Processing (Table 9), XRD (
(61) 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.
(62) TABLE-US-00021 TABLE 9 Processing Rheology Formulation Torque (Nm) Nylon 12 105 7 102 8 104 9 107
(63) TABLE-US-00022 TABLE 10 Mechanical Peformance Notched Tensile Tensile Impact Modulus Strength Elongation Strength Formulation (MPa) (MPa) at break (%) (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%
(64) TABLE-US-00023 TABLE 11 Fire Testing Cone Calorimetry Peak Mass Heat 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 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
(65) TABLE-US-00024 TABLE 12 Vertical Burn Results UL94 FAA 12 s FAA 12 s 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
(66) TABLE-US-00025 TABLE 13 Vertical Burn, Radiant Panel and Smoke Test Results (0.75 mm) Smoke Formulation FAA 12 s (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
(67) 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
(68) Processing rheology (Table 15), XRD (
(69) 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 nanometer 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 12 s 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.
(70) TABLE-US-00027 TABLE 15 Processing Rheology Extruder Torque Formulation (Nm) Nylon 12 105 11 105 12 106 13 103
(71) 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%
(72) TABLE-US-00029 TABLE 17 Fire Performance-Vertical Burn UL94 12 s FAA 12 s FAA 60 s 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
(73) 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
(74) 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
(75) 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
(76) 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
(77) TABLE-US-00032 TABLE 20 Mechanical Performance Conditions Notched Processing Screw Tensile Tensile Impact Temp. speed Through- Modulus Strength Strength (° 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%
(78) TABLE-US-00033 TABLE 21 FAA 12 s Vertical Burn Performance (0.75 mm thickness) Conditions Flame out Processing Screw speed Through-put Time Temp. (° 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
(79) 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)
(80) 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.
(81) 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
(82) The following example illustrates the effect of different conventional flame retardants on the performance (Table 23) of nylon12 incorporating an IOH2 (Example 2).
(83) 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.
(84) 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
(85) The following example illustrates the effect of removing components of the fire resistant formulation on resultant fire performance (Table 24)
(86) 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.
(87) 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
(88) The following example illustrates the mechanical and 12 s 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 60 s FAA type vertical burn results for the above mentioned formulations. Mechanical and vertical burn performance of Nylon12 formulations incorporating IOH2, melamine cyanurate and magnesium hydroxide of different surface functionality and particle size distribution is provided in Table 28.
(89) 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 nanometer 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.
(90) 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)
(91) 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
(92) 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
(93) TABLE-US-00040 TABLE 28 Performance of materials, incorporating IOH2 melamine cyanurate and Mg(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
(94) 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
(95) 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).
(96) 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
(97) The following example illustrates the performance of nylon6 and nylon66 formulations incorporating IOH2 and melamine cyanurate
(98) The results indicate that IOH2 at least partially dispersed on a nanometer scale in conjunction with melamine cyanurate provides excellent mechanical and vertical burn performance relative to nylon6 and nylon66.
(99) 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
(100) The following example shows the XRD of nylon 12 formulations incorporating modified and intercalated hectorite (Example 6) dispersed at least partially on a nanometer scale (
(101) 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 nanometer scale (
(102) TABLE-US-00043 TABLE 31 Vertical Burn Performance FAA 12 s Vertical burn, Formulation Ext. Time (s)(0.75 mm) Nylon12 Fail (68) 50 Pass (2)
Example 18
(103) 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.
(104) 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.
(105) 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
(106) 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
(107) This example provides the mechanical and fire performance (Table 34) of nylon12 formulations incorporating IOH2, conventional flame retardants and minor component of stabilizer.
(108) 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.
(109) 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
(110) 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 (
(111)
(112) 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.