COMPRESSIBLE FIRE RETARDANT FOAM

Abstract

The present invention relates to a material for thermal and/or acoustic insulation which consists of at least 300 phr, preferably at least 400 phr, but less than 1200 phr, preferably less than 1000 phr, especially preferred less than 800 phr ingredients in total, comprising 100 phr of at least one polymer, of which at least 60 phr, preferably at least 70 phr, especially preferred at least 80 phr is chlorinated polyethylene (CPE), the process of manufacturing such material, wherein the polymeric material is expanded by decomposition of a chemical blowing agent.

Claims

1. An expanded polymeric material consisting of at least 300 phr, but less than 1200 phr ingredients in total, the material comprising: 100 phr of at least one polymer, of which at least 60 phr is chlorinated polyethylene (CPE); wherein the chlorinated polyethylene (CPE) shows a chlorine content of at least 35 wt % according to ISO 1158; and at least 20 phr of at least one further chlorinated organic polymer.

2. (canceled)

3. (canceled)

4. The material according to claim 1, which is crosslinked by a crosslinking system.

5. The material according to claim 4, wherein the crosslinking system comprises thiadiazole and/or peroxides and/or sulphur crosslinking systems.

6. The material according to claim 1, further comprising at least one plasticiser that is present in the formulation in at least 50 phr.

7. The material according to claim 6, wherein at least one plasticizer is a chlorinated plasticizer selected from chlorinated paraffin and/or chlorinated fatty acid substituted glycerin and/or chlorinated alpha-olefin, wherein the chlorinated plasticizer has a chlorine content of at least 20 wt % according to DIN 53474.

8. The material according to claim 6, wherein at least one plasticiser is a phosphate plasticizer.

9. The material according to claim 1, further comprising at least 100 phr of at least one inorganic filler.

10. The material according to claim 9, wherein the inorganic filler contains a metal.

11. The material according to claim 1, further comprising at least one synergist.

12. The material according to claim 1, which is expanded to a density of less than 100 kg/m.sup.3 according to DIN EN ISO 845.

13. The material according to claim 1, having a maximum elongation at break of at least 50% according to ISO 37.

14. The material according to claim 1, which has a closed cell structure, determined by a vacuum water absorption of <5.0% according to ASTM D 1056.

15. The material according to claim 1, which is glued with standard chloroprene based contact adhesives, acrylate and/or styrene block copolymer based pressure sensitive adhesives (PSAs) and/or hot melt adhesives.

16. A process for manufacturing the expanded polymeric material according to claim 1, wherein the polymeric material is expanded by decomposition of a chemical blowing agent.

17. (canceled)

18. An expanded polymeric material consisting of at least 300 phr, but less than 1200 phr ingredients in total, the material comprising: 100 phr of at least one polymer, of which at least 60 phr is chlorinated polyethylene (CPE); wherein the chlorinated polyethylene (CPE) shows a chlorine content of at least 35 wt % according to ISO 1158; wherein the material is crosslinked by a crosslinking system comprising thiadiazole.

19. The material according to claim 18, further comprising at least one plasticiser that is present in the formulation in at least 50 phr.

20. The material according to claim 19, wherein at least one plasticizer is selected from a chlorinated plasticizer or a phosphate plasticizer.

21. The material according to claim 18, further comprising at least 100 phr of at least one inorganic filler, wherein the inorganic filler contains a metal.

22. The material according to claim 18, further comprising at least one synergist selected from a Bi or Zn based material.

23. An expanded polymeric material which consists of at least 300 phr, but less than 1200 phr ingredients in total, the material comprising: 100 phr of at least one polymer, of which at least 60 phr is chlorinated polyethylene (CPE); at least 200 phr of at least one inorganic filler, wherein the inorganic filler contains a metal; at least 30 phr of at least one plasticizer selected from a chlorinated plasticizer or a phosphate plasticizer; at least one synergist selected from a Bi or Zn based material; wherein the chlorinated polyethylene (CPE) shows a chlorine content of at least 35 wt % according to ISO 1158, wherein the material is crosslinked by a crosslinking system comprising thiadiazole and/or peroxides.

24. The material according to claim 18, which is expanded to a density of less than 100 kg/m.sup.3 according to DIN EN ISO 845.

25. The material according to claim 18, having a maximum elongation at break of at least 50% according to ISO 37.

26. The material according to claim 18, which has a closed cell structure, determined according to ASTM D 1056.

27. The material according to claim 23, which is expanded to a density of less than 100 kg/m.sup.3 according to DIN EN ISO 845.

28. The material according to claim 23, having a maximum elongation at break of at least 50% according to ISO 37.

29. The material according to claim 23, which has a closed cell structure, determined according to ASTM D 1056.

Description

EXAMPLES

[0050] The following examples and comparative examples have been produced in a three step production process: the mixing of compounds, the extrusion process and the expansion and crosslinking of the extrudate.

[0051] The compounds have been mixed in an internal mixer with an average mixing time of 10 minutes and an average dumping temperature of 120 C. The compounds have then been homogenized further on a roller mill and the crosslinking system and azodicarbonamide as blowing (expansion) agent were added as it is standard in the industry.

[0052] The extrusion has been performed on a strip feeded single screw vacuum extruder providing raw unexpanded sheets and tubes. Those have then been crosslinked and expanded simultaneously in a hot air oven cascade of 5 ovens to sheets of 25 mm wall thickness and tubes of 25 mm wall thickness and 22 mm inner diameter. Table 1 lists the raw materials used for the compounds. Table 2 gives an overview of all tested materials. Table 3 shows the recipes of the compounds. Examples 11a, 11 b and 11c are produced from the same compound but differ in the achieved density of the expanded product.

TABLE-US-00001 TABLE 1 Raw materials Chemical name Trade name Supplier Chlorinated Polyethylene (CPE) Elaslen 401AY Showa Denko, Japan Polychloroprene (CR) Baypren 611 Lanxess, Germany Chlorosulfonated Polyethylene (CSM) TOSO-CSM TS-430 Tosoh Corporation Polyvinylchloride (PVC) Vinnolit S3265 Vinnolit, Germany Aluminium Trihydroxide (ATH) Martinal 111LE Martinswerk, Germany Carbon Black (CB) Corax N550 Evonik Industries, Germany Chloroparaffin (CP) Chlorparaffin 50 Leuna, Germany Zinc Stannate (ZS) ZB 467 Great Lakes, U.S.A. Bismutoxychloride (BO) BiOCl4 Alpha Chemicals Diphenyl 2-ethylhexyl phosphate (DPO) Disflamoll DPO Lanxess, Germany Antimonytrioxide (SB) Antimontrioxid GMS-Chemie, Germany

[0053] Table 2 shows an overview of the tested materials and their compositions. All materials except from competitor material 6 were available as 25 mm sheets and tubes in 25 mm wall thickness and 22 mm inner diameter. Competitor material 6 is only available as tubes. It was tested in 25 mm wall thickness and 22 mm inner diameter.

TABLE-US-00002 TABLE 2 Comparative materials and innovative examples No. Base Polymer Flame retardant Miscellaneous 1* AF/Armaflex NBR/PVC Brominated/antimony ATH filled, crosslinked 2* NH/Armaflex NBR halogen free ATH filled, crosslinked 3* HT/Armaflex EPDM Brominated/antimony ATH filled, crosslinked 4* KaiflexKK NBR/PVC Brominated/antimony ATH filled, crosslinked 5* KaiflexBluEco NBR halogen free ATH filled, crosslinked 6* Competitor material PE/CPE halogenated >80% polymer, not crosslinked 7* Armaflex Ultima CR chlorinated paraffin ATH filled, crosslinked 8 CPE/CR chlorinated paraffin ATH filled, crosslinked 9 CPE/PVC chlorinated paraffin ATH filled, crosslinked 10 CPE/CSM chlorinated paraffin ATH filled, crosslinked 11 CPE chlorinated paraffin ATH filled, crosslinked 12 CPE chlorinated paraffin ATH filled, crosslinked 13 CPE chlorinated paraffin ATH filled, crosslinked 14 CPE DPO ATH filled, crosslinked 15 CPE DPO low ATH filled, crosslinked *= comparative materials

TABLE-US-00003 TABLE 3 CPE compounds (all innovative examples) crosslinking system Composition (in phr = parts Metal No. per hundred rubber) oxide Thiadiazol Peroxide 8 70 CPE, 30 CR, 240 ATH, 90 CP, X 3 BO, 2 CB 9 80 CPE, 20 PVC, 280 ATH, X 120 CP, 3 ZS, 2 CB 10 60 CPE, 40 CSM, 180 ATH, X 100 CP, 2 ZS, 2 CB 11 100 CPE, 220 ATH, 110 CP, X 2 ZS, 1 CB 12 100 CPE, 240 ATH, 130 CP, X 3 BO, 2 CB 13 100 CPE, 240 ATH, 130 CP, X 3 SB, 2 CB 14 100 CPE, 240 ATH, 80 DPO, X 3 BO, 2 CB 15 100 CPE, 130 ATH, 40 DPO, X 360, 2 CB

[0054] Table 4 presents the flammability test results of the different materials. The SBI test has been performed on both tubes and sheets, where possible, DIN 4102-1 has been performed on tubes only and ASTM E84 and the EN45545 have been performed on sheets only.

TABLE-US-00004 TABLE 4 Flammability test results SBI of sheets/tubes tubes sheets sheets Material EN 13823/13501-1 DIN 4102-1 ASTM E84 EN 45545 1* B-s3, d0 B1 08/300 R1/HL1 2* E/D-s3, d0 /B2 48/333 R1/HL1 3* D-s3, d0/C-s3, d0 B2/B1 08/311 4* C-s3, d0 B1 5* E R1/HL1 6* /B-s1, d0 B1 7* B-s2, d0/B-s1, d0 B1 05/40 R1/HL2 8 B-s2, d0/B-s1, d0 B1 12/40 R1/HL2 9 B-s2, d0/B-s1, d0 B1 07/47 R1/HL2 10 B-s2, d0/B-s1, d0 B1 09/41 R1/HL2 11a B-s2, d0/B-s1, d0 B1 11/42 R1/HL2 12 B-s2, d0/B-s1, d0 B1 05/48 R1/HL2 13 B-s3, d0/B-s2, d0 B1 09/132 R1/HL2 14 B-s2, d0/B-s1, d0 B1 18/32 R1/HL2 15 C-s3, d0/C-s2, d0 B1 109/82 R1/HL2 *= comparative materials

[0055] Table 5 gives an overview of the measured mechanical properties of the materials and their insulation properties. Minimum service temperature has been determined by measurement of the lowest temperature at which the material remains flexible and can be bent without permanent deformation. Samples 11a-11c show the dependence of materials properties from different densities made of the same compound. Linear shrinkage has been determined by length measurement on tubes before and after conditioning of samples at 110 C. for 24 h.

TABLE-US-00005 TABLE 5 Mechanical and insulation properties UV lin. Thermal Water Stability max. shrinkage conductivity Vapour min. Xenon Elongation DIN Density EN 12667 Barrier softening service weathering at break ISO 2796 ISO 845 [W m-1 K-1] EN 12086 temp. temp. test 1000 h ISO 37 [%] Material [kg/m.sup.3] at 0 C., WVT [ C.] [ C.] Grade [%] 4 h,100 C. 1* 56 0.033 10000 110 50 3 90 2.0 2* 61 0.035 4000 110 50 3 90 2.0 3* 65 0.036 4000 150 50 2 100 7.0 4* 59 0.034 10000 110 50 3 90 5* 66 0.037 6000 110 50 3 90 6* 32 0.040 6000 100 0 1 20 7* 61 0.040 7000 110 40 4 100 3.0 8 48 0.035 10000 120 40 2 110 2.0 9 49 0.036 10000 140 40 1 100 3.0 10 48 0.035 9000 140 40 2 110 2.0 11a 50 0.035 8500 150 40 1 100 1.5 11b 61 0.038 9200 150 40 1 110 1.5 11c 87 0.041 10000 150 40 1 110 2.0 12 51 0.035 8000 150 40 1 100 1.5 13 50 0.036 9000 150 40 1 100 1.5 14 52 0.036 8500 150 60 1 100 1.5 15 50 0.036 7000 150 60 1 110 1.5 *= comparative materials