FIREPROOF POLYMER ADDITIVE, METHOD OF ITS PRODUCTION AND APPLICATION

Abstract

Fireproof polymer additive is created from non-toxic components of a melt of waterless mixture of ammonium polyphosphate, pentaerythritol, and melamine and/or urea, with temperature ranging from 240° C. to 350° C.; the common melt is maintained at the said temperature for at least 30 seconds, subsequently it is left to cool and the solidified melt is disintegrated into particles smaller than 200 μm, preferably smaller than 50 μm, especially preferably smaller than 10 μm. Each of the two components can at the entry from 5 to 95% of the mass of the final mixture. In case of the realization with three or four components, each of the components can at the entry from 5 to 50% of the mass of the final mixture. The fireproof polymer additive is added to the basic material in ratio of 1% to 80% of the share of the mass of the resulting matter.

Claims

1. A fireproof polymer additive in a loose form at least partial polymerization of a waterless melt of ammonium polyphosphate and pentaerythritol.

2. The fireproof polymer additive according to the claim 1, wherein each of the components have at an entry a share of 5% to 95% of a mass of the resulting additive.

3. The fireproof polymer additive according to claim 1, further comprising melamine and/or a urea.

4. The fireproof polymer additive, according to claim 3, wherein the melamine and/or a urea has at the entry the share of 5 to 50% of the mass of the resulting additive.

5. The fireproof polymer additive according to claim 1, wherein the at least partial polymerization of a waterless melt of ammonium polyphosphate is ammonium polyphosphate of a second crystalline phase.

6. The fireproof polymer additive, according to claim 1, wherein the fireproof polymer has a granulation below 200 μm.

7. A method of a production of a fireproof polymer additive in a loose form, the method comprising the steps of: producing a waterless polymerization from ammonium polyphosphate and pentaerythritol, heating the waterless chain polymerization from ammonium polyphosphate and pentaerythritol to a temperature ranging from 240° C. to 350° C. to produce a melt, maintaining the melt at a temperature ranging from 240° C. to 350° C. for at least 30 seconds; cooling the melt to produce a solidified melt, disintegrating the solidified melt into particles.

8. The method according to claim 7, wherein the ammonium polyphosphate is ammonium polyphosphate of a second crystalline phase and wherein heating step is at a temperature ranging from 285° C. to 350° C.

9. The method according to claim 7, the melt contains: ammonium polyphosphate from 5% to 95% of the mass and pentaerythritol from 5% to 95% of the mass.

10. The method according to claim 7, wherein the melamine is dissolved from the loose waterless form at the heightened temperature is part of the melt.

11. The method according to claim 10, the melamine is melamine cyanurate, melamine borate, melamine polyphosphate, melamine diphosphate, melamine pyrophosphate, or melamine phosphate.

12. The method according to claim 7, further including the steps of dissolving urea from the loose or solid waterless form at the heightened temperature is part of the melt.

13. The method according to claim 10, wherein the melt contains: ammonium polyphosphate from 5% to 50% of the mass; pentaerythritol from 5% to 50% of the mass; melamine and/or the urea from 5% to 50% of the mass.

14. The method according to claim 7, wherein the solidified melt is disintegrated into particles smaller than 200 μm.

15. The method according to claim 7, wherein firstly, the unheated entry components in the dry waterless state are mechanically mixed and subsequently a mixture of a solid particles of the entry components is heated to the melt.

16. The method according to claim 7, wherein: the ammonium polyphosphate and the pentaerythritol are independently heated until are melted and subsequently mixed into the melt. or the ammonium polyphosphate and the pentaerythritol are simultaneously mixed and heated into the melt.

17. (canceled)

18. The method according to the claim 7, wherein the melt is disintegrated after cooling below 150° C.

19. A method of an application of the fireproof polymer additive produced according to claim 7, wherein the fireproof polymer additive is added to a basic material in a ratio of 1% to 80% of the mass of the final matter.

20. The method according to claim 19, wherein the fireproof polymer additive is added to the basic material with the melting temperature less than 175° C. and subsequently during a treatment of the plastic basic material it is at least partially melted.

21. The method according to the claim 19, wherein the fireproof polymer additive is: mixed into a granulate of a thermoplastic before its injection into a mold; or mixed into a thermoset plastic, into an epoxy resin, a polyester resin, a vinyl ester resin, a polyurethane base, an elastomeric rubber, or a bioplastic.

22. (canceled)

Description

BRIEF DESCRIPTION OF DRAWINGS

[0037] The invention is further disclosed by means of FIG. 1, which shows a thermogravimetric melting curve of the fireproof polymer additive with three entry components. The highest measured temperature of melting at 177.8° C. shows a creation of a new substance different from the entry components, whose melting temperature is above 240° C. The depicted particular peak of the curve is for illustration purposes only—it is related to the particular chosen ration of the entry components and cannot be interpreted as limiting the scope of protection.

EXAMPLES OF REALIZATION

Example 1

[0038] In this example two components of the melt are weighed and chosen followingly: ammonium polyphosphate in amount of 50 mass parts, pentaerythritol in amount of 50 mass parts. The entry components in loose, waterless form are placed into the common vessel where they are mixed and subsequently heated beyond 285° C., whereby a common melt is produced which is mixed and maintained at the temperature beyond 285° C. for at least two minutes. Subsequently the melt of the new created substance is left to cool. The melt of the new substance solidifies at the temperature below 175° C. In this example the cooling continues until the temperature of the environment is reached. Subsequently, the solidified matter of the melt is milled in ball mill and then it proceeds to the separating sieve with 50 μm, whereby the larger particles return to the ball mill.

[0039] Resulting fireproof polymer additive in the loose powder state is packed into bags and subsequently added to the granulate of thermoplastic before its injection into a mold where at least partial melting of the fireproof polymer additive takes place at temperatures beyond 175° C.

Example 2

[0040] In this example three components of the melt are weighed and chosen followingly: ammonium polyphosphate in amount of 50 mass parts, pentaerythritol in amount of 30 mass parts and melamine in the amount of 20 mass parts. The entry components in loose, waterless form are placed into the common vessel where they are mixed and subsequently heated beyond 270° C., whereby a common melt is produced which is mixed and maintained at the temperature beyond 270° C. for at least three minutes. Subsequently the melt of the new created substance is left to cool. The melt of the new substance solidifies at the temperature below 175° C., pursuant to FIG. 1. In this example the cooling continues until the temperature of the environment is reached. Subsequently, the solidified matter of the melt is milled in ball mill and then it proceeds to the separating sieve with 100 μm.

[0041] Resulting fireproof polymer additive in the loose powder state is packed into bags and subsequently added to the granulate of thermoplastic before its injection into a mold where at least partial melting of the fireproof polymer additive takes place at temperatures beyond 175° C.

Example 3

[0042] In this example three components of the melt are weighed and chosen followingly: ammonium polyphosphate in amount of 40 mass parts, pentaerythritol in amount of 40 mass parts and melamine in the amount of 20 mass parts.

[0043] Entry components are independently melted at temperatures beyond 250° C. and subsequently mixed into the common melt, where polymerization takes place for at least 5 minutes. The melt of the resulting substance is cooled and disintegrated into fraction below 10 μm.

Example 4

[0044] In this example three components of the melt are weighed and chosen followingly: ammonium polyphosphate in amount of 40 mass parts, pentaerythritol in amount of 20 mass parts and urea in the amount of 30 mass parts.

[0045] Entry components are independently melted at temperatures beyond 240° C. and subsequently mixed into the common melt, where polymerization takes place for at least 5 minutes. The melt of the resulting substance is cooled and disintegrated into fraction below 50 μm.

Example 5

[0046] In this example four components of the melt are weighed and chosen followingly: ammonium polyphosphate in amount of 30 mass parts, pentaerythritol in amount of 20 mass parts, melamine in the amount of 25 mass parts and urea in the amount of 25 mass parts.

[0047] Entry components are melted together at temperature beyond 260° C. while they are continuously mixed, whereby the polymerization takes place in the common melt for at least 4 minutes. The melt of the resulting substance is cooled and disintegrated into fraction below 200 μm.

Example 6

[0048] Fireproof polymer additive in the loose state with the fraction below 5 μm is mixed into one of the two components of the epoxy resin with a share of 20% of the mass within an overall mass of the resulting epoxy resin. The epoxy resin is used in the electrotechnics industry, it has high fire resistance and even with a fire exposure it shows no smokiness.

Example 7

[0049] In this example three components of the melt are weighed and chosen followingly: ammonium polyphosphate in amount of 34 mass parts, pentaerythritol in amount of 33 mass parts and melamine in the amount of 33 mass parts. The resulting melt of the new substance solidifies at the temperature below 175° C.

INDUSTRIAL APPLICABILITY

[0050] Industrial applicability of the invention is obvious. According to this invention it is possible to industrially and repeatedly produce and use fireproof polymer additive with high efficacy, which has no toxic components.