US20070004838A1 - Ultra-low petroleum plastics - Google Patents
Ultra-low petroleum plastics Download PDFInfo
- Publication number
- US20070004838A1 US20070004838A1 US11/174,321 US17432105A US2007004838A1 US 20070004838 A1 US20070004838 A1 US 20070004838A1 US 17432105 A US17432105 A US 17432105A US 2007004838 A1 US2007004838 A1 US 2007004838A1
- Authority
- US
- United States
- Prior art keywords
- composition
- plastic
- polymer
- weight
- inorganic salt
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 229920003023 plastic Polymers 0.000 title claims abstract description 89
- 239000004033 plastic Substances 0.000 title claims abstract description 89
- 239000003208 petroleum Substances 0.000 title abstract description 23
- 239000000203 mixture Substances 0.000 claims abstract description 141
- 229910017053 inorganic salt Inorganic materials 0.000 claims abstract description 64
- 239000002245 particle Substances 0.000 claims abstract description 38
- 239000000779 smoke Substances 0.000 claims abstract description 15
- 239000011230 binding agent Substances 0.000 claims abstract description 10
- 229920000642 polymer Polymers 0.000 claims description 73
- -1 polyethylene Polymers 0.000 claims description 35
- 229920001169 thermoplastic Polymers 0.000 claims description 32
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 claims description 27
- 229910052921 ammonium sulfate Inorganic materials 0.000 claims description 24
- 235000011130 ammonium sulphate Nutrition 0.000 claims description 24
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 16
- 239000000654 additive Substances 0.000 claims description 16
- 239000004014 plasticizer Substances 0.000 claims description 16
- 229920002554 vinyl polymer Polymers 0.000 claims description 15
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 14
- 229920000098 polyolefin Polymers 0.000 claims description 14
- 229920001187 thermosetting polymer Polymers 0.000 claims description 14
- 150000003839 salts Chemical class 0.000 claims description 10
- 229920000728 polyester Polymers 0.000 claims description 9
- 229920001225 polyester resin Polymers 0.000 claims description 9
- 239000004645 polyester resin Substances 0.000 claims description 9
- 229920002635 polyurethane Polymers 0.000 claims description 9
- 239000004814 polyurethane Substances 0.000 claims description 9
- 239000004952 Polyamide Substances 0.000 claims description 8
- 239000004698 Polyethylene Substances 0.000 claims description 8
- 229920002647 polyamide Polymers 0.000 claims description 8
- 239000004634 thermosetting polymer Substances 0.000 claims description 8
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 7
- 150000003863 ammonium salts Chemical class 0.000 claims description 7
- 239000003822 epoxy resin Substances 0.000 claims description 6
- 239000000945 filler Substances 0.000 claims description 6
- 229920000647 polyepoxide Polymers 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 6
- 229920005989 resin Polymers 0.000 claims description 6
- 239000011347 resin Substances 0.000 claims description 6
- 239000003381 stabilizer Substances 0.000 claims description 6
- 239000004609 Impact Modifier Substances 0.000 claims description 5
- 239000004743 Polypropylene Substances 0.000 claims description 5
- 229920001155 polypropylene Polymers 0.000 claims description 5
- 238000002156 mixing Methods 0.000 claims description 4
- 239000000049 pigment Substances 0.000 claims description 3
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 53
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 26
- 229920000915 polyvinyl chloride Polymers 0.000 description 20
- 239000004800 polyvinyl chloride Substances 0.000 description 19
- 239000000178 monomer Substances 0.000 description 16
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 9
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 8
- 229920001778 nylon Polymers 0.000 description 7
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 7
- 239000004677 Nylon Substances 0.000 description 6
- 239000004416 thermosoftening plastic Substances 0.000 description 6
- 229920000305 Nylon 6,10 Polymers 0.000 description 5
- 239000002253 acid Substances 0.000 description 5
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 5
- 239000004305 biphenyl Substances 0.000 description 5
- 235000010290 biphenyl Nutrition 0.000 description 5
- 229920001577 copolymer Polymers 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 239000011236 particulate material Substances 0.000 description 5
- ZUOUZKKEUPVFJK-UHFFFAOYSA-N phenylbenzene Natural products C1=CC=CC=C1C1=CC=CC=C1 ZUOUZKKEUPVFJK-UHFFFAOYSA-N 0.000 description 5
- 239000004417 polycarbonate Substances 0.000 description 5
- 229920000515 polycarbonate Polymers 0.000 description 5
- 239000000047 product Substances 0.000 description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 4
- PEEHTFAAVSWFBL-UHFFFAOYSA-N Maleimide Chemical compound O=C1NC(=O)C=C1 PEEHTFAAVSWFBL-UHFFFAOYSA-N 0.000 description 4
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- 229920001684 low density polyethylene Polymers 0.000 description 4
- 239000004702 low-density polyethylene Substances 0.000 description 4
- 229920001707 polybutylene terephthalate Polymers 0.000 description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 description 4
- 239000005020 polyethylene terephthalate Substances 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 3
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 3
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 3
- 239000000460 chlorine Substances 0.000 description 3
- MNNHAPBLZZVQHP-UHFFFAOYSA-N diammonium hydrogen phosphate Chemical compound [NH4+].[NH4+].OP([O-])([O-])=O MNNHAPBLZZVQHP-UHFFFAOYSA-N 0.000 description 3
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 239000003063 flame retardant Substances 0.000 description 3
- 229920001903 high density polyethylene Polymers 0.000 description 3
- 239000004700 high-density polyethylene Substances 0.000 description 3
- 229920001519 homopolymer Polymers 0.000 description 3
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 3
- 238000001746 injection moulding Methods 0.000 description 3
- 235000011007 phosphoric acid Nutrition 0.000 description 3
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 3
- 229920000058 polyacrylate Polymers 0.000 description 3
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 3
- 239000004810 polytetrafluoroethylene Substances 0.000 description 3
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical compound OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 230000001629 suppression Effects 0.000 description 3
- ZGEGCLOFRBLKSE-UHFFFAOYSA-N 1-Heptene Chemical compound CCCCCC=C ZGEGCLOFRBLKSE-UHFFFAOYSA-N 0.000 description 2
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 2
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 2
- JRZJOMJEPLMPRA-UHFFFAOYSA-N 1-nonene Chemical compound CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 2
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 2
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 2
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 description 2
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 2
- IYMZEPRSPLASMS-UHFFFAOYSA-N 3-phenylpyrrole-2,5-dione Chemical compound O=C1NC(=O)C(C=2C=CC=CC=2)=C1 IYMZEPRSPLASMS-UHFFFAOYSA-N 0.000 description 2
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 2
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- 239000004254 Ammonium phosphate Substances 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000004604 Blowing Agent Substances 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 239000004970 Chain extender Substances 0.000 description 2
- 239000004801 Chlorinated PVC Substances 0.000 description 2
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 2
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 2
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- QIGBRXMKCJKVMJ-UHFFFAOYSA-N Hydroquinone Chemical compound OC1=CC=C(O)C=C1 QIGBRXMKCJKVMJ-UHFFFAOYSA-N 0.000 description 2
- JHWNWJKBPDFINM-UHFFFAOYSA-N Laurolactam Chemical compound O=C1CCCCCCCCCCCN1 JHWNWJKBPDFINM-UHFFFAOYSA-N 0.000 description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 2
- 229920000299 Nylon 12 Polymers 0.000 description 2
- 229920002292 Nylon 6 Polymers 0.000 description 2
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
- 239000004697 Polyetherimide Substances 0.000 description 2
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 2
- ZJCCRDAZUWHFQH-UHFFFAOYSA-N Trimethylolpropane Chemical compound CCC(CO)(CO)CO ZJCCRDAZUWHFQH-UHFFFAOYSA-N 0.000 description 2
- 239000007983 Tris buffer Substances 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 125000000217 alkyl group Chemical group 0.000 description 2
- 235000019289 ammonium phosphates Nutrition 0.000 description 2
- 125000003118 aryl group Chemical group 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 2
- 239000008116 calcium stearate Substances 0.000 description 2
- 235000013539 calcium stearate Nutrition 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 229920000457 chlorinated polyvinyl chloride Polymers 0.000 description 2
- 229910052801 chlorine Inorganic materials 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 125000000753 cycloalkyl group Chemical group 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 150000001991 dicarboxylic acids Chemical class 0.000 description 2
- 125000005442 diisocyanate group Chemical group 0.000 description 2
- 230000003292 diminished effect Effects 0.000 description 2
- 150000002009 diols Chemical class 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- JBKVHLHDHHXQEQ-UHFFFAOYSA-N epsilon-caprolactam Chemical compound O=C1CCCCCN1 JBKVHLHDHHXQEQ-UHFFFAOYSA-N 0.000 description 2
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 2
- 150000002367 halogens Chemical group 0.000 description 2
- 239000012760 heat stabilizer Substances 0.000 description 2
- 239000011261 inert gas Substances 0.000 description 2
- QWTDNUCVQCZILF-UHFFFAOYSA-N isopentane Chemical compound CCC(C)C QWTDNUCVQCZILF-UHFFFAOYSA-N 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- BDJRBEYXGGNYIS-UHFFFAOYSA-N nonanedioic acid Chemical compound OC(=O)CCCCCCCC(O)=O BDJRBEYXGGNYIS-UHFFFAOYSA-N 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 235000019198 oils Nutrition 0.000 description 2
- 239000012188 paraffin wax Substances 0.000 description 2
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 2
- 239000003209 petroleum derivative Substances 0.000 description 2
- 229920001230 polyarylate Polymers 0.000 description 2
- 229920002530 polyetherether ketone Polymers 0.000 description 2
- 229920001601 polyetherimide Polymers 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 239000004926 polymethyl methacrylate Substances 0.000 description 2
- 229920000069 polyphenylene sulfide Polymers 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 229920006345 thermoplastic polyamide Polymers 0.000 description 2
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 2
- 229920001567 vinyl ester resin Polymers 0.000 description 2
- DTGKSKDOIYIVQL-WEDXCCLWSA-N (+)-borneol Chemical group C1C[C@@]2(C)[C@@H](O)C[C@@H]1C2(C)C DTGKSKDOIYIVQL-WEDXCCLWSA-N 0.000 description 1
- 125000003837 (C1-C20) alkyl group Chemical group 0.000 description 1
- 229910019670 (NH4)H2PO4 Inorganic materials 0.000 description 1
- JNPCNDJVEUEFBO-UHFFFAOYSA-N 1-butylpyrrole-2,5-dione Chemical compound CCCCN1C(=O)C=CC1=O JNPCNDJVEUEFBO-UHFFFAOYSA-N 0.000 description 1
- BQTPKSBXMONSJI-UHFFFAOYSA-N 1-cyclohexylpyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C1CCCCC1 BQTPKSBXMONSJI-UHFFFAOYSA-N 0.000 description 1
- SJLLJZNSZJHXQN-UHFFFAOYSA-N 1-dodecylpyrrole-2,5-dione Chemical compound CCCCCCCCCCCCN1C(=O)C=CC1=O SJLLJZNSZJHXQN-UHFFFAOYSA-N 0.000 description 1
- OEVVKKAVYQFQNV-UHFFFAOYSA-N 1-ethenyl-2,4-dimethylbenzene Chemical compound CC1=CC=C(C=C)C(C)=C1 OEVVKKAVYQFQNV-UHFFFAOYSA-N 0.000 description 1
- NVZWEEGUWXZOKI-UHFFFAOYSA-N 1-ethenyl-2-methylbenzene Chemical compound CC1=CC=CC=C1C=C NVZWEEGUWXZOKI-UHFFFAOYSA-N 0.000 description 1
- JZHGRUMIRATHIU-UHFFFAOYSA-N 1-ethenyl-3-methylbenzene Chemical compound CC1=CC=CC(C=C)=C1 JZHGRUMIRATHIU-UHFFFAOYSA-N 0.000 description 1
- FBPVUBVZRPURIU-UHFFFAOYSA-N 1-hexylpyrrole-2,5-dione Chemical compound CCCCCCN1C(=O)C=CC1=O FBPVUBVZRPURIU-UHFFFAOYSA-N 0.000 description 1
- KIKBJYQCJJXCBZ-UHFFFAOYSA-N 1-octylpyrrole-2,5-dione Chemical compound CCCCCCCCN1C(=O)C=CC1=O KIKBJYQCJJXCBZ-UHFFFAOYSA-N 0.000 description 1
- HIDBROSJWZYGSZ-UHFFFAOYSA-N 1-phenylpyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C1=CC=CC=C1 HIDBROSJWZYGSZ-UHFFFAOYSA-N 0.000 description 1
- NQDOCLXQTQYUDH-UHFFFAOYSA-N 1-propan-2-ylpyrrole-2,5-dione Chemical compound CC(C)N1C(=O)C=CC1=O NQDOCLXQTQYUDH-UHFFFAOYSA-N 0.000 description 1
- QEDJMOONZLUIMC-UHFFFAOYSA-N 1-tert-butyl-4-ethenylbenzene Chemical compound CC(C)(C)C1=CC=C(C=C)C=C1 QEDJMOONZLUIMC-UHFFFAOYSA-N 0.000 description 1
- GUOSQNAUYHMCRU-UHFFFAOYSA-N 11-Aminoundecanoic acid Chemical compound NCCCCCCCCCCC(O)=O GUOSQNAUYHMCRU-UHFFFAOYSA-N 0.000 description 1
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- WWILHZQYNPQALT-UHFFFAOYSA-N 2-methyl-2-morpholin-4-ylpropanal Chemical compound O=CC(C)(C)N1CCOCC1 WWILHZQYNPQALT-UHFFFAOYSA-N 0.000 description 1
- WMRCTEPOPAZMMN-UHFFFAOYSA-N 2-undecylpropanedioic acid Chemical compound CCCCCCCCCCCC(C(O)=O)C(O)=O WMRCTEPOPAZMMN-UHFFFAOYSA-N 0.000 description 1
- VEORPZCZECFIRK-UHFFFAOYSA-N 3,3',5,5'-tetrabromobisphenol A Chemical compound C=1C(Br)=C(O)C(Br)=CC=1C(C)(C)C1=CC(Br)=C(O)C(Br)=C1 VEORPZCZECFIRK-UHFFFAOYSA-N 0.000 description 1
- NEQFBGHQPUXOFH-UHFFFAOYSA-N 4-(4-carboxyphenyl)benzoic acid Chemical compound C1=CC(C(=O)O)=CC=C1C1=CC=C(C(O)=O)C=C1 NEQFBGHQPUXOFH-UHFFFAOYSA-N 0.000 description 1
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- UMPGNGRIGSEMTC-UHFFFAOYSA-N 4-[1-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexyl]phenol Chemical compound C1C(C)CC(C)(C)CC1(C=1C=CC(O)=CC=1)C1=CC=C(O)C=C1 UMPGNGRIGSEMTC-UHFFFAOYSA-N 0.000 description 1
- ODJUOZPKKHIEOZ-UHFFFAOYSA-N 4-[2-(4-hydroxy-3,5-dimethylphenyl)propan-2-yl]-2,6-dimethylphenol Chemical compound CC1=C(O)C(C)=CC(C(C)(C)C=2C=C(C)C(O)=C(C)C=2)=C1 ODJUOZPKKHIEOZ-UHFFFAOYSA-N 0.000 description 1
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- 229920001342 Bakelite® Polymers 0.000 description 1
- UUAGPGQUHZVJBQ-UHFFFAOYSA-N Bisphenol A bis(2-hydroxyethyl)ether Chemical compound C=1C=C(OCCO)C=CC=1C(C)(C)C1=CC=C(OCCO)C=C1 UUAGPGQUHZVJBQ-UHFFFAOYSA-N 0.000 description 1
- SDDLEVPIDBLVHC-UHFFFAOYSA-N Bisphenol Z Chemical compound C1=CC(O)=CC=C1C1(C=2C=CC(O)=CC=2)CCCCC1 SDDLEVPIDBLVHC-UHFFFAOYSA-N 0.000 description 1
- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical compound [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 description 1
- GAWIXWVDTYZWAW-UHFFFAOYSA-N C[CH]O Chemical group C[CH]O GAWIXWVDTYZWAW-UHFFFAOYSA-N 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- 229920001634 Copolyester Polymers 0.000 description 1
- OTMSDBZUPAUEDD-UHFFFAOYSA-N Ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- PXGOKWXKJXAPGV-UHFFFAOYSA-N Fluorine Chemical compound FF PXGOKWXKJXAPGV-UHFFFAOYSA-N 0.000 description 1
- 241001251094 Formica Species 0.000 description 1
- 244000068988 Glycine max Species 0.000 description 1
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- UEZVMMHDMIWARA-UHFFFAOYSA-N Metaphosphoric acid Chemical class OP(=O)=O UEZVMMHDMIWARA-UHFFFAOYSA-N 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 229920000571 Nylon 11 Polymers 0.000 description 1
- 229920003189 Nylon 4,6 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 229920008285 Poly(ether ketone) PEK Polymers 0.000 description 1
- 229920012266 Poly(ether sulfone) PES Polymers 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 229920002396 Polyurea Polymers 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- KYPYTERUKNKOLP-UHFFFAOYSA-N Tetrachlorobisphenol A Chemical compound C=1C(Cl)=C(O)C(Cl)=CC=1C(C)(C)C1=CC(Cl)=C(O)C(Cl)=C1 KYPYTERUKNKOLP-UHFFFAOYSA-N 0.000 description 1
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 1
- 239000004699 Ultra-high molecular weight polyethylene Substances 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- YMOONIIMQBGTDU-VOTSOKGWSA-N [(e)-2-bromoethenyl]benzene Chemical compound Br\C=C\C1=CC=CC=C1 YMOONIIMQBGTDU-VOTSOKGWSA-N 0.000 description 1
- 150000003926 acrylamides Chemical class 0.000 description 1
- 229920006243 acrylic copolymer Polymers 0.000 description 1
- 229920006397 acrylic thermoplastic Polymers 0.000 description 1
- 125000003647 acryloyl group Chemical group O=C([*])C([H])=C([H])[H] 0.000 description 1
- 239000001361 adipic acid Substances 0.000 description 1
- 235000011037 adipic acid Nutrition 0.000 description 1
- 229920003232 aliphatic polyester Polymers 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 125000005907 alkyl ester group Chemical group 0.000 description 1
- 125000000746 allylic group Chemical group 0.000 description 1
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 1
- 150000001413 amino acids Chemical class 0.000 description 1
- BIGPRXCJEDHCLP-UHFFFAOYSA-N ammonium bisulfate Chemical compound [NH4+].OS([O-])(=O)=O BIGPRXCJEDHCLP-UHFFFAOYSA-N 0.000 description 1
- LFVGISIMTYGQHF-UHFFFAOYSA-N ammonium dihydrogen phosphate Chemical compound [NH4+].OP(O)([O-])=O LFVGISIMTYGQHF-UHFFFAOYSA-N 0.000 description 1
- 229910000387 ammonium dihydrogen phosphate Inorganic materials 0.000 description 1
- 229910000148 ammonium phosphate Inorganic materials 0.000 description 1
- ZRIUUUJAJJNDSS-UHFFFAOYSA-N ammonium phosphates Chemical class [NH4+].[NH4+].[NH4+].[O-]P([O-])([O-])=O ZRIUUUJAJJNDSS-UHFFFAOYSA-N 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000004637 bakelite Substances 0.000 description 1
- 238000000498 ball milling Methods 0.000 description 1
- VCCBEIPGXKNHFW-UHFFFAOYSA-N biphenyl-4,4'-diol Chemical group C1=CC(O)=CC=C1C1=CC=C(O)C=C1 VCCBEIPGXKNHFW-UHFFFAOYSA-N 0.000 description 1
- 238000000071 blow moulding Methods 0.000 description 1
- GDTBXPJZTBHREO-UHFFFAOYSA-N bromine Substances BrBr GDTBXPJZTBHREO-UHFFFAOYSA-N 0.000 description 1
- 229910052794 bromium Inorganic materials 0.000 description 1
- MPMBRWOOISTHJV-UHFFFAOYSA-N but-1-enylbenzene Chemical compound CCC=CC1=CC=CC=C1 MPMBRWOOISTHJV-UHFFFAOYSA-N 0.000 description 1
- AHVSBLJQPUGBIO-UHFFFAOYSA-N buta-1,3-diene;nitroso prop-2-enoate;styrene Chemical compound C=CC=C.C=CC(=O)ON=O.C=CC1=CC=CC=C1 AHVSBLJQPUGBIO-UHFFFAOYSA-N 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- CDQSJQSWAWPGKG-UHFFFAOYSA-N butane-1,1-diol Chemical compound CCCC(O)O CDQSJQSWAWPGKG-UHFFFAOYSA-N 0.000 description 1
- 235000010216 calcium carbonate Nutrition 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- UUAGAQFQZIEFAH-UHFFFAOYSA-N chlorotrifluoroethylene Chemical group FC(F)=C(F)Cl UUAGAQFQZIEFAH-UHFFFAOYSA-N 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
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- 239000007859 condensation product Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
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- 239000002285 corn oil Substances 0.000 description 1
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- QYQADNCHXSEGJT-UHFFFAOYSA-N cyclohexane-1,1-dicarboxylate;hydron Chemical compound OC(=O)C1(C(O)=O)CCCCC1 QYQADNCHXSEGJT-UHFFFAOYSA-N 0.000 description 1
- VEIOBOXBGYWJIT-UHFFFAOYSA-N cyclohexane;methanol Chemical compound OC.OC.C1CCCCC1 VEIOBOXBGYWJIT-UHFFFAOYSA-N 0.000 description 1
- 125000000113 cyclohexyl group Chemical group [H]C1([H])C([H])([H])C([H])([H])C([H])(*)C([H])([H])C1([H])[H] 0.000 description 1
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- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000002939 deleterious effect Effects 0.000 description 1
- 150000004985 diamines Chemical class 0.000 description 1
- 229910000388 diammonium phosphate Inorganic materials 0.000 description 1
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- 239000000539 dimer Substances 0.000 description 1
- AFABGHUZZDYHJO-UHFFFAOYSA-N dimethyl butane Natural products CCCC(C)C AFABGHUZZDYHJO-UHFFFAOYSA-N 0.000 description 1
- ROORDVPLFPIABK-UHFFFAOYSA-N diphenyl carbonate Chemical compound C=1C=CC=CC=1OC(=O)OC1=CC=CC=C1 ROORDVPLFPIABK-UHFFFAOYSA-N 0.000 description 1
- XPPKVPWEQAFLFU-UHFFFAOYSA-N diphosphoric acid Chemical class OP(O)(=O)OP(O)(O)=O XPPKVPWEQAFLFU-UHFFFAOYSA-N 0.000 description 1
- 125000003438 dodecyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000007706 flame test Methods 0.000 description 1
- 229910052731 fluorine Inorganic materials 0.000 description 1
- 239000011737 fluorine Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 125000003055 glycidyl group Chemical group C(C1CO1)* 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 125000001072 heteroaryl group Chemical group 0.000 description 1
- HCDGVLDPFQMKDK-UHFFFAOYSA-N hexafluoropropylene Chemical group FC(F)=C(F)C(F)(F)F HCDGVLDPFQMKDK-UHFFFAOYSA-N 0.000 description 1
- ACCCMOQWYVYDOT-UHFFFAOYSA-N hexane-1,1-diol Chemical compound CCCCCC(O)O ACCCMOQWYVYDOT-UHFFFAOYSA-N 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 125000002768 hydroxyalkyl group Chemical group 0.000 description 1
- 125000000959 isobutyl group Chemical group [H]C([H])([H])C([H])(C([H])([H])[H])C([H])([H])* 0.000 description 1
- 125000001449 isopropyl group Chemical group [H]C([H])([H])C([H])(*)C([H])([H])[H] 0.000 description 1
- 150000003951 lactams Chemical class 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000010297 mechanical methods and process Methods 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- 150000002734 metacrylic acid derivatives Chemical class 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 235000019837 monoammonium phosphate Nutrition 0.000 description 1
- 239000006012 monoammonium phosphate Substances 0.000 description 1
- 150000002763 monocarboxylic acids Chemical class 0.000 description 1
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- SEEYREPSKCQBBF-UHFFFAOYSA-N n-methylmaleimide Chemical compound CN1C(=O)C=CC1=O SEEYREPSKCQBBF-UHFFFAOYSA-N 0.000 description 1
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 1
- 239000011234 nano-particulate material Substances 0.000 description 1
- 239000002105 nanoparticle Substances 0.000 description 1
- KYTZHLUVELPASH-UHFFFAOYSA-N naphthalene-1,2-dicarboxylic acid Chemical compound C1=CC=CC2=C(C(O)=O)C(C(=O)O)=CC=C21 KYTZHLUVELPASH-UHFFFAOYSA-N 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- OEIJHBUUFURJLI-UHFFFAOYSA-N octane-1,8-diol Chemical compound OCCCCCCCCO OEIJHBUUFURJLI-UHFFFAOYSA-N 0.000 description 1
- MMSLOZQEMPDGPI-UHFFFAOYSA-N p-Mentha-1,3,5,8-tetraene Chemical compound CC(=C)C1=CC=C(C)C=C1 MMSLOZQEMPDGPI-UHFFFAOYSA-N 0.000 description 1
- 235000019809 paraffin wax Nutrition 0.000 description 1
- 239000013618 particulate matter Substances 0.000 description 1
- UWJJYHHHVWZFEP-UHFFFAOYSA-N pentane-1,1-diol Chemical compound CCCCC(O)O UWJJYHHHVWZFEP-UHFFFAOYSA-N 0.000 description 1
- 235000019271 petrolatum Nutrition 0.000 description 1
- 150000002989 phenols Chemical class 0.000 description 1
- XNGIFLGASWRNHJ-UHFFFAOYSA-L phthalate(2-) Chemical compound [O-]C(=O)C1=CC=CC=C1C([O-])=O XNGIFLGASWRNHJ-UHFFFAOYSA-L 0.000 description 1
- 229920002492 poly(sulfone) Polymers 0.000 description 1
- 229920002312 polyamide-imide Polymers 0.000 description 1
- 229920000768 polyamine Polymers 0.000 description 1
- 229920001083 polybutene Polymers 0.000 description 1
- 238000006068 polycondensation reaction Methods 0.000 description 1
- 239000004848 polyfunctional curative Substances 0.000 description 1
- 229920006123 polyhexamethylene isophthalamide Polymers 0.000 description 1
- 229920000306 polymethylpentene Polymers 0.000 description 1
- 239000011116 polymethylpentene Substances 0.000 description 1
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 235000013824 polyphenols Nutrition 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- ARJOQCYCJMAIFR-UHFFFAOYSA-N prop-2-enoyl prop-2-enoate Chemical compound C=CC(=O)OC(=O)C=C ARJOQCYCJMAIFR-UHFFFAOYSA-N 0.000 description 1
- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 229940005657 pyrophosphoric acid Drugs 0.000 description 1
- HNJBEVLQSNELDL-UHFFFAOYSA-N pyrrolidin-2-one Chemical compound O=C1CCCN1 HNJBEVLQSNELDL-UHFFFAOYSA-N 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000001175 rotational moulding Methods 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229920005573 silicon-containing polymer Polymers 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000003549 soybean oil Substances 0.000 description 1
- 235000012424 soybean oil Nutrition 0.000 description 1
- 239000011145 styrene acrylonitrile resin Substances 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 description 1
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 1
- 238000003856 thermoforming Methods 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 235000010215 titanium dioxide Nutrition 0.000 description 1
- 230000001988 toxicity Effects 0.000 description 1
- 231100000419 toxicity Toxicity 0.000 description 1
- 238000005809 transesterification reaction Methods 0.000 description 1
- 229920000785 ultra high molecular weight polyethylene Polymers 0.000 description 1
- 229920001862 ultra low molecular weight polyethylene Polymers 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
- 150000003955 ε-lactams Chemical class 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/49—Phosphorus-containing compounds
- C08K5/51—Phosphorus bound to oxygen
- C08K5/52—Phosphorus bound to oxygen only
- C08K5/521—Esters of phosphoric acids, e.g. of H3PO4
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
- C08K3/016—Flame-proofing or flame-retarding additives
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/30—Sulfur-, selenium- or tellurium-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/32—Phosphorus-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L75/00—Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
- C08L75/04—Polyurethanes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L75/00—Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
- C08L75/04—Polyurethanes
- C08L75/06—Polyurethanes from polyesters
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/30—Sulfur-, selenium- or tellurium-containing compounds
- C08K2003/3045—Sulfates
- C08K2003/3054—Ammonium sulfates
Definitions
- the present invention relates generally to plastic-like materials having diminished contents of petroleum-derived products.
- the invention also relates to fire retardant plastic-like materials.
- plastic materials comprise synthetic polymers derived predominately from petroleum.
- the disadvantages of such petroleum-derived products are well known and include, for example, the rapid depletion of the world's petroleum reserves, the deleterious environmental consequences resulting from the poor biodegradability of petroleum-derived plastic materials, and the fluctuating cost of plastic production with the price of oil.
- Even conventional “low petroleum” plastics such as polyvinyl chloride (“PVC”), which comprises approximately 43% by weight petroleum feedstock products, suffer from these disadvantages.
- PVC polyvinyl chloride
- the present invention provides plastic-like materials having interesting physical and mechanical properties, chemical properties such as fire retardancy and smoke suppression superior to conventional plastics, and diminished petroleum-derived material content as compared to conventional plastics.
- plastic-like materials comprising between about 20 to about 80% by weight of an inorganic salt can be obtained which have physical, mechanical, and chemical properties that are useful for many of the applications in which conventional plastics are employed. Some properties, such as fire retardancy, smoke suppression, toxicity of smoke release, and heat resistance are substantially improved as compared to conventional plastics. Importantly, the plastic-like materials or the invention are cheaper to produce than conventional plastics.
- a plastic-like composition comprising about 10% to about 80% by weight of a plastic polymer and about 20% to about 80% by weight of an inorganic salt in particulate form.
- the weight percentage of inorganic salt is above 50% and tends toward the upper limit of the given range.
- the composition has a reduced propensity to ignite or smoke in the presence of heat or flame as compared to the thermoplastic polymer which it comprises.
- the polymer may be either a thermoplastic polymer or a thermosetting polymer.
- the plastic is a thermosetting plastic such as, for example, an epoxy resin.
- the plastic polymer is a thermoplastic polymer such as, for example, a polyvinyl, polyacrylate, polyurethane, polycarbonate, polyester, polyamide, or polyolefin polymer, or any combination thereof.
- the inorganic salt according to one embodiment is a salt of phosphoric acid or sulfuric acid and in particular an ammonium salt of those acids.
- the inorganic salt is provided having a relatively small particle size, such as, for example between about 0.001 ⁇ m to about 1,000 ⁇ m. Within this range, it has been found to be desirable to provide inorganic salts with particle sizes tending toward the lower limit.
- plastic-like refers to a material which comprises less polymeric material than conventional plastics but is nonetheless capable of being molded or formed with the application of heat or pressure in the same manner as a conventional plastic material.
- the “plastic-like” materials of the present invention share many of the physical and mechanical properties of conventional plastics, i.e., they may be shaped using any of the conventional techniques useful for shaping conventional plastics, including for example, injection molding and rolling.
- the plastic-like compositions of the invention comprise far less polymeric material than conventional plastics.
- pill form is mean to expansively include any form of solid ammonium sulfate including but not limited to, crystalline particles, microcrystalline particles, micronized particles, nanoparticles, amorphous particles, and the like.
- thermoplastic is meant to have its ordinary meaning in the art and generally refers to plastics which are capable of repeatedly softening when heated and hardening when cooled.
- thermosetting is also meant to have its ordinary meaning in the art and generally refers to plastics which cannot be re-melted after being formed.
- the plastic-like composition comprises about 10% to about 80% by weight of a plastic polymer and about 20% to about 80% by weight of an inorganic salt in particulate form.
- the composition has a reduced propensity to ignite or smoke in the presence of heat or flame as compared to the plastic polymer, alone.
- the composition is non-flammable when subjected to flame testing, such as U.S. Government standard for flammability resistance FAR 25.853(b).
- the plastic polymeric component of the present invention may be any plastic (i.e., a thermoplastic or a thermosetting).
- the plastic is a thermoplastic polymer.
- acrylics such as polymethyl methacrylate (PMMA), acryl-nitrite butadiene styrene (ABS), high density polyethylene (HDPE), low density polyethylene (LDPE), polycarbonates, polyesters, including polybutylene terephthalate (PBT) and polyethylene terephthalate (PET), polyamides, such as nylon, polyolefins, including but not limited to polyethylene and polypropylene, polyorganosiloxane rubber, polytetrafluoroethylene (PTFE), polystyrene (PS), silicone polymers and copolymers, styrene-acrylonitrile (SAN), vinyl plastics, including but
- PES poly(phenylene sulfide)
- PES polysulfone
- PES polyethersulfone
- PES polyurea
- PEK polyetherketone
- PEEK polyetheretherketone
- thermoplastic polymers are those formed by polymerization of vinyl monomers, including, but not limited to olefinic monomers such as, for example, ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene, wherein the alkyl substituents may be either linear or branched or may be cycloalkyl constituents.
- Vinyl aromatic monomers such as styrene and other aryl or hetero-aryl substituted vinyl monomers are also suitable.
- Exemplary styrenic monomers include styrene, ⁇ -methylstyrene, p-tertiary butylstyrene, p-methylstyrene, o-methylstyrene, m-methylstyrene, 2,4-dimethylstyrene, ethylstyrene, ⁇ -methyl-p-methyl styrene, bromostyrene, and the like.
- homopolymers and copolymers of olefinic monomers are disclosed in U.S. Pat. No. 6,890,991 to Fujimoto et al, the disclosure of which is hereby incorporated by reference, and include low density polyethylene, ultra-low-density polyethylene, ultra-super-low density polyethylene, linear low density polyethylene, high density polyethylene, ultrahigh molecular weight polyethylene, polypropylene, ethylene-propylene copolymer, polymethylpentene, polybutene, and the like.
- the vinyl monomers may also be vinyl halides. Desirable halogen substituents are chlorine, bromine, fluorine or combinations thereof. A preferred halogen is chlorine as in the case of the vinyl chloride monomer.
- PVC polyvinyl chloride
- Other halogenated monomers include without limitation vinylidene chloride, tetrafluoroethylene, chlorotrifluoroethylene, and hexafluoropropylene.
- vinyl plastic includes homopolymers and copolymers of vinyl monomers.
- PVC polyvinyl plastic
- PVC polyvinyl plastic
- PVC polyvinyl plastic
- PVC polyvinyl plastic
- PVC polyvinyl plastic
- PVC polyvinyl plastic
- PVC polyvinyl plastic
- vinyl esters such as vinyl acetate, vinylidene chloride
- alkyl esters of unsaturated mono- or dicarboxylic acids such as acrylic acid, methacrylic acid, maleic acid and fumaric acid, including vinyl acetate, acrylate esters, and methacrylate esters, and olefins such as ethylene and propylene, and the like.
- thermoplastic polymers of the invention include, but are not limited to, those disclosed in U.S. Pat. No. 6,875,832 to White et al., the disclosure of which is hereby incorporated by reference, namely allylic monomers, (meth)acrylic acid, (meth)acrylates, (meth)acrylamide, N- and N,N-disubstituted (meth)acrylamides, vinyl esters of carboxylic acids and mixtures thereof.
- thermoplastic polymer of the invention may be a thermoplastic acrylic polymer or copolymer such as describe in, for example, U.S. Pat. No. 4,473,679 to Falk et al and 4,452,941 to Kishida et al., the disclosures of which are hereby incorporated by reference. Special mention may be made of the acrylate monomers disclosed in U.S. Pat. No.
- 6,875,832 which include, without limitation, C 1 -C 20 alkyl (meth)acrylates (including linear or branched alkyls and cycloalkyls) which include, but are not limited to, methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, iso-butyl (meth)acrylate, tert-butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, isobornyl (meth)acrylate, cyclohexyl (meth)acrylate, 3,3,5-trimethylcyclohexyl (meth)acrylate and isocane (meth)acrylate; oxirane functional (meth)acrylates which include, but are not limited to, glycidyl (meth)acrylate, 3,
- the residues may each independently be residues of monomers having more than one (meth)acryloyl group, such as (meth)acrylic anhydride, diethyleneglycol bis(meth)acrylate, 4,4′-isopropylidenediphenol bis(meth)acrylate (bisphenol A di(meth)acrylate), alkoxylated 4,4′-isopropylidenediphenol bis(meth)acrylate, trimethylolpropane tris(meth)acrylate and alkoxylated trimethylolpropane tris(meth)acrylate.
- (meth)acrylic anhydride diethyleneglycol bis(meth)acrylate
- 4,4′-isopropylidenediphenol bis(meth)acrylate bisphenol A di(meth)acrylate
- alkoxylated 4,4′-isopropylidenediphenol bis(meth)acrylate trimethylolpropane tris(meth)acrylate
- the thermoplastic polymers may also contain maleimide monomers such as maleimide, N-methyl maleimide, N-iso-propyl maleimide, N-butyl maleimide, N-hexyl maleimide, N-octyl maleimide, N-dodecyl maleimide, N-cyclohexyl maleimide, N-phenyl maleimide, N-2-methyl maleimide, N-2,3-dimethyl phenyl maleimide, N-2,4-dimethyl phenyl maleimide, N-2,3-diethyl phenyl maleimide, N-2,4-diethyl phenyl maleimide, N-2,3-dibutyl phenyl maleimide, N-2,4-dibutyl phenyl maleimide, N-2,6-dimethyl phenyl maleimide, N-2,3-dichlorophenyl maleimide, N-2,4-dichloropheny
- the thermoplastic polymers may comprise a polyester resin as described in, for example, U.S. Pat. No. 6,890,991 to Fujimoto et al, the disclosure of which is hereby incorporated by reference.
- polyester resins are obtained by the polycondensation reaction of one or more dicarboxylic acids such as, for example, terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid, 4,4′-diphenyldicarboxylic acid, diphenyletherdicarboxylic acid, ⁇ , ⁇ -bis(4-carboxyphenoxy)ethane, adipic acid, sebacic acid, azelaic acid, decanedicarboxylic acid, dodecanedicarboxylic acid, cyclohexanedicarboxylic acid and dimer acid, or ester-forming derivarives thereof, and one or more glycols such as, for example, ethylene glycol, propylene glycol, butanediol,
- the polyester resin may be either a homopolyester or a copolyester.
- Other exemplary thermoplastic polyesters are disclosed in, for example, U.S. Pat. No. 6,809,151 to Lacroix et al., the disclosure of which is hereby incorporated by reference.
- Particularly interesting polyesters are polybutylene terephthalate (PBT) and polyethylene terephthalate (PET).
- thermoplastic polyurethanes materials include those disclosed in U.S. Pat. No. 6,881,856 to Tanaka et al., the disclosure of which is hereby incorporated by reference.
- theremoplastic polyurethanes are obtained by reaction of polyethercarbonate diols with a diisocyanate and a chain extender, such as a polyol or polyamine compound, by a polyurethane-producing reaction.
- the exemplary polyethercarbonate diols, diisocyanates, and chain extenders disclosed in U.S. Pat. No. 6,881,856 are hereby incorporated by reference.
- thermoplastic polymers of the invention may also comprise thermoplastic polyamides (nylons) such as those disclosed in U.S. Pat. No. 6,870,005 to Lieberman et al., the disclosure of which is hereby incorporated by reference.
- These thermoplastic polyamides may be prepared by polymerization of, for example, one or more epsilon lactams such as caprolactam, pyrrolidone, lauryllactam and aminoundecanoic lactam, or amino acid, or by condensation of dibasic acids and diamines.
- Exemplary polyamides include polycaprolactam (nylon 6), polylauryllactam (nylon 12), polyhexamethylenedipamide (nylon 6,6), polyhexamethyleneazelamide (nylon 6,9), polyhexamethylenesebacamide (nylon 6,10), polyhexamethyleneisophthalamide (nylon 6,10), the condensation product of 11-aminoundecanoic acid (nylon 11), polytetramethyleneadipamide (nylon 4,6), polyhexamethyleneazelaamide (nylon 6,9), polyhexamethylenesebacamide (nylon 6,10), polyhexamethylenedodecanediamide (nylon 6,12), and polydodecanemethylenedodecanamide (nylon 12,12).
- Other suitable nylon resins are disclosed in, for example, U.S. Pat. No. 6,861,470, the disclosure of which is hereby incorporated by reference.
- Thermoplastic polycarbonate plastics are also well known in the art and include, for example, those described in U.S. Pat. No. 5,756,641 to Kuhling et al., the disclosure of which is hereby incorporated by reference. Such polycarbonates are formed by transesterification of aromatic diphenols with carboxylic acid diaryl esters.
- Exemplary diphenols include, without limitation, 4,4′-dihydroxydiphenyl, 4,4′-dihydroxydiphenyl sulphide, 2,2-bis-(4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dibromo-4-hydroxyphenyl)-propane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, and 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.
- Exemplary carboxylic acid diesters include without limitation di-C 6 -C 20 -aryl esters, such as the diesters of phenol or of alkyl-substituted phenols. Special mention may be made of diphenyl carbonate or dicresyl carbonate.
- Particularly interesting polymers according to the invention comprise polyvinyls, polyacrylates, polyurethanes, polycarbonates, polyesters, polyamides, polyolefins, and combinations thereof.
- Polyvinyl and polyolefin polymers are especially interesting polymers according to the invention.
- the plastic component may be a thermosetting plastic such as, without limitation, epoxy resin, polyester resin, natural rubbers such as latex, melamine plastics such as Formica®, phenolics such as Bakelite, urea-formaldehyde, and the like.
- thermosetting plastic such as, without limitation, epoxy resin, polyester resin, natural rubbers such as latex, melamine plastics such as Formica®, phenolics such as Bakelite, urea-formaldehyde, and the like.
- compositions of the present invention also include as an essential component an inorganic salt. While it is contemplated that a wide variety of inorganic salts will be useful in the practice of the invention, it is advantageous to employ a fire extinguishing inorganic salt. Particular mention may be made of inorganic salts of phosphoric acid, metaphosphoric acid, orthophosphoric acid, pyrophosphoric acid, polyphophoric acid, sulfuric acid, and hydrochloric acid. Ammonium salts are especially useful.
- particularly interesting inorganic salts include but are not limited to ammonium phosphates, such as (NH 4 )H 2 PO 4 (mono-ammonium phosphate or ammonium phosphate) and (NH 4 ) 2 HPO 4 (di-ammonium phosphate), and ammonium sulfates, including (NH 4 ) 2 SO 4 (ammonium sulfate or di-ammonium sulfate) and (NH 4 )HSO 4 (ammonium hydrogen sulfate or ammonium bisulfate), and (NH 4 ) 2 Cl.
- the inorganic salt comprises ammonium sulfates, especially (NH 4 ) 2 SO 4 . Combinations of any of the foregoing inorganic salts are also contemplated to be useful.
- the inorganic salt is in particulate form. While it is contemplated that any size inorganic salt particulate material will be useful in the practice of the invention, preferred materials will have average particle diameters of below about 1 mm. Accordingly, in one embodiment of the invention, the inorganic salt particulate material has an average particle size of about 0.001 ⁇ m to about 1,000 ⁇ m. In another embodiment, the inorganic salt particulate material has an average particle size of about 0.01 ⁇ m to about 300 ⁇ m. In particularly interesting embodiments, the particle size of the inorganic salt is between about 0.1 to about 30 ⁇ m, 1 and about 10 ⁇ m, and about 5 to about 8 ⁇ m. Further, the invention embraces embodiments within the range of 0.001 ⁇ m to about 1,000 ⁇ m wherein the lower and upper limits are increased or decreased by intervals of 5 ⁇ m, each such sub-range being an embodiment of the invention.
- the particles size distribution of the inorganic salt particulate material may be selected by any known method in the art, including the use of mesh sieves.
- the particle sizes which will pass through standard (Tyler or BS-410) mesh sizes are well known in the art.
- Inorganic salt particulate materials which have an average particle size sufficiently small to pass through any of the standard Tyler mesh sizes are contemplated to be useful in the practice of the present invention. Accordingly, with regard to the standard Tyler mesh sizes, the invention embraces embodiments having particle sizes of less than about 297, 250, 210, 177, 149, 105, 74, 62, 53, 44, 37, 20, 10, and about 5 ⁇ m, respectively.
- compositions of the invention generally comprise the plastic polymer between about 10% and about 80% by weight and comprise the inorganic salt between about 20% to 80% by weight, with the proviso the sum of the weight % of each component not exceed 100%.
- the lower limit of the weight ranges of inorganic salt may be at least 26%, 27%, 28%, or at least 29% by weight.
- the invention also contemplates sub-ranges within the foregoing ranges wherein the lower and/or upper limits are increased or decreased, respectively, by intervals of 5 weight %, each such sub-range being an embodiment of the invention.
- the compositions comprise the plastic polymer between about 10% and about 60% by weight and comprise the inorganic salt between about 30% to 80% by weight. In another embodiment, the compositions comprise the plastic polymer between about 10% and about 50% by weight and the inorganic salt between about 40% to 80% by weight. In another embodiment, the compositions comprise the plastic polymer between about 10% and about 40% by weight and the inorganic salt between about 50% to 80% by weight. In a further embodiment, the compositions comprise the plastic polymer between about 10% and about 30% by weight and the inorganic salt between about 60% to 80% by weight. In an yet another embodiment, the compositions comprise the plastic polymer between about 10% and about 20% by weight and the inorganic salt between about 70% to 80% by weight.
- the weight ratio of plastic polymer to inorganic salt is typically in the range of about 1:8 to about 5:1, including embodiments of 1:7 to about 4:1, 1:5 to about 3:1, 1:3 to about 2:1, and 1:2 to about 1:1.
- plastic-like compositions of the invention comprises: (a) about 10 to about 80% by weight of a plastic polymer; and (b) about 10 to about 80% by weight of an inorganic salt having an average particle size between about 0.001 and about 300 ⁇ m; said composition having a reduced propensity to ignite or smoke in the presence of heat or flame as compared to said plastic polymer alone; with the proviso that when the weight of the inorganic salt component is ammonium sulfate comprising 25% or less by weight of the composition, the plastic-like composition is substantially non-intumescent.
- compositions of the invention comprise a plurality of inorganic salt particles, such as ammonium sulfate in particulate form, having any of the average particle sizes set forth above, held in a homogenous physical unit by a plastic polymeric binder.
- homogenous physical unit it is meant that the inorganic salt and the plastic are not readily separable from one another.
- the bulk of the compositions of the invention may be provided by the inorganic salt.
- the plastic material serves as a binder to hold the particulate matrix in place and impart flexibility, ductility, and the like, to the compositions.
- compositions of the invention may comprise additives.
- additives may comprise between about 0.01% and about 35% by weight of the composition. In one embodiment, the additives comprises about 20% by weight of the composition.
- the additives include all those well known in the art, including but not limited to, intumescent additives, plasticizers, stabilizers, fillers, blending resins, pigments, and additives, as well known to one skilled in the art. Any plasticizer, stabilizer, filler, or other additive known in the art may be used in the present invention. Suitable plasticizer, stabilizer, fillers, and other additives, include but are not limited to, those disclosed in U.S. Pat. No. 6,706,820 to Kumaki, et al., U.S. Pat. No. 5,552,484 to Enomoto, and U.S. Pat. No. 4,042,556 to Yoshinaga, the contents of which are hereby incorporated by reference herein.
- the plastics may further comprise U.V. stabilizers, colorants, and impact modifiers.
- Additives including, but not limited to, low flammability oils such as soybean and corn oils, calcium carbonate, calcium stearate, titanium dioxide, paraffin wax, oxidized PE lubricant, phthalate plasticizers, heat stabilizers, impact modifiers, and intumescent additives are particularly notable.
- the plasticizer 2-ethyl hexyl diphenyl (Santicizer® 141, Ferro Corp.) has been found useful in the practice of the invention. Thinners for processing may also be desirable in some applications.
- blowing agents such as for example, chlorinated fluorocarbons, HCFCs, butane, isopentane, carbon dioxide, nitrogen, argon, and the like, may also be used to produce foamed products, all in accordance with well known practice in the art.
- Methods for making foamed plastic are disclosed in, for example, U.S. Pat. Nos. 3,983,296 and 4,120,833 to Purvis, et al., U.S. Pat. No. 4,017,657 to Foley, et al., U.S. Pat. No. 4,042,556 to Yoshinaga, U.S. Pat. Nos. 5,391,585 and 5,324,461 to Grohman, U.S. Pat. No.
- compositions of the invention may be formed in any technique conventional for forming thermoplastics or thermosettings, including, for example, extrusion, injection molding, blow molding, rotomolding, thermoforming, calandering, and compression molding.
- the materials of the invention may be extruded in the same manner as conventional plastics, as disclosed in, for example, U.S. Pat. No. 6,350,400 to Piotrowski, U.S. Pat. No. 4,322,170 to Papenmeier; U.S. Pat. No. 3,983,186 to Eilers, et al., M. J. Stevens, “Extruder Principals and Operation”, Elsevier Applied Science Publishers, New York, N.Y. (1985), and C.
- compositions are suitable for injection molding and the like.
- compositions of the invention may also be formed by rolling under heat as is also well known in the art.
- compositions of the invention contain far less polymeric material derived from petroleum than conventional plastics.
- conventional compounded PVC has the makeup given in Table II. TABLE II Material Weight Percent (based on PVC resin) PVC Resin 100 Impact Modifier 5.0 Heat Stabilizer 0.8 Filler (CaCO 3 ) 10 Calcium Stearate 1.4 Processing Aid 0.8 Oxidized PE Lubricant 0.15 Paraffin Wax 1.2 TiO 2 2.0
- conventional compounded PVC comprises approximately 83% by weight polyvinyl chloride polymer, which itself comprises 43% by weight petroleum-derived material.
- polymers such as PVC which is generally considered to be a “low-petroleum” content material, contains 0.36 pounds (or 36% by weight) of polymer derived from petroleum for every pound of compounded PVC.
- Table III provides three exemplary low-petroleum content formulations of the invention.
- the compounded PVC resin is mixed with ammonium sulfate and plasticizer in the ratios given.
- ammonium Compounded Weight % of sulfate Plasticizer PVC petroleum-derived Sample (wt. %) (wt. %) (wt. %) (wt. %) polymeric component 1 60 19 21 7.6 2 55 19 26 9.4 3 50 19 31 11.2
- the benefits of the present invention as applied to high petroleum content plastics are immediately apparent.
- the petroleum based content of such plastics can be reduced by at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or 80%, each being considered an embodiment of the invention. It is contemplated that even greater reductions in the petroleum based content of plastic materials are achievable with the present invention.
- compositions of the invention have a reduced propensity to ignite or smoke in the presence of heat or flame as compared to the plastic binder material alone. This property is believed to arise from the reduced petroleum content of the materials and the fact that flame retardant inorganic salts, such as ammonium sulfate, release inert gases (i.e., N 2 ) upon decomposition with heat. Accordingly, in particularly desirable embodiments, the inorganic salt is a flame retardant inorganic salt.
- the compositions of the invention are substantially non-intumescent, in the absence of added intumescent material. This does not preclude, however, the addition of minor amounts of intumescent additives such as intumescent catalysts, carbonifics, and/or blowing agents to the compositions.
- micronized ammonium sulfate from Example 1 was mixed with approximately 21 gm of a standard compounded PVC (see Table II) and approximately 19 gm pounds of the 2-ethyl hexyl diphenyl plasticizer Santicizer® 141 (Ferro Corp.). The mixture was formed into sheets having a thickness of about 30 mil with twin rollers operating at 380° F. for about five minutes, or until homogeneous.
- Example 1 Approximately 55 gm pounds of micronized ammonium sulfate from Example 1 was mixed with approximately 26 gm pounds of a standard compounded PVC (see Table II) and approximately 19 gm pounds of the 2-ethyl hexyl diphenyl plasticizer Santicizer® 141 (Ferro Corp.). The mixture was formed into sheets having a thickness of about 30 mil with twin rollers operating at 380° F. for about five minutes, or until homogeneous.
- a standard compounded PVC see Table II
- 2-ethyl hexyl diphenyl plasticizer Santicizer® 141 Ferro Corp.
- the material also passed the U.S. Government standard for flammability resistance FAR 25.853. That test involves subjecting a panel to edge burning by a flame maintained at 1550° F. for a period of 60 seconds and requires that the material be self-extinguishing before 15 seconds and that it be non-dripping. After subjecting the material to flame for 60 seconds, there was no flaming or dripping of the material.
- micronized ammonium sulfate from Example 1 was mixed with approximately 31 gm of a standard compounded PVC (see Table II) and approximately 19 gm pounds of the 2-ethyl hexyl diphenyl plasticizer Santicizer® 141 (Ferro Corp.). The mixture was formed into sheets having a thickness of about 30 mil with twin rollers operating at 380° F. for about five minutes, or until homogeneous.
- micronized ammonium sulfate from Example 1 was mixed with approximately 46 gm pounds of a standard compounded PVC (see Table II) and approximately 19 gm pounds of the 2-ethyl hexyl diphenyl plasticizer Santicizer® 141 (Ferro Corp.). The mixture was formed into sheets having a thickness of about 30 mil with twin rollers operating at 380° F. for about five minutes, or until homogeneous.
- the material also passed the U.S. Government standard for flammability resistance FAR 25.853(b). That test involves subjecting a panel to edge burning by a flame maintained at 1550° F. for a period of 12 seconds and requires that the material be self-extinguishing before 15 seconds and that it be non-dripping. After subjecting the material to flame for 12 seconds, there was no flaming or dripping of the material.
- This example provides a material according to the invention wherein the polymeric binder is a thermosetting polymer.
- 48 parts of polyester resin 48 (approximately 4 pounds) was mixed with 52 parts (approximately 4.5 pounds) ammonium sulfate from Example 1 in one gallon container. The composition was mixed until homogenous, about 5 minutes, with a drill blade. After mixing, about 900 drops of a methyl ethyl ketone peroxide (MEKP) hardener was added to set the material.
- MEKP methyl ethyl ketone peroxide
Abstract
Description
- The present invention relates generally to plastic-like materials having diminished contents of petroleum-derived products. The invention also relates to fire retardant plastic-like materials.
- Conventional plastic materials comprise synthetic polymers derived predominately from petroleum. The disadvantages of such petroleum-derived products are well known and include, for example, the rapid depletion of the world's petroleum reserves, the deleterious environmental consequences resulting from the poor biodegradability of petroleum-derived plastic materials, and the fluctuating cost of plastic production with the price of oil. Even conventional “low petroleum” plastics such as polyvinyl chloride (“PVC”), which comprises approximately 43% by weight petroleum feedstock products, suffer from these disadvantages.
- Accordingly, it has long been desirable to decrease the petroleum content of plastic products. Unfortunately, satisfactory alternatives to petroleum-derived plastic materials have not heretofore been commercially viable. Therefore, there is a need in the art for plastic or plastic-like materials which have a reduced petroleum content as compared to conventional plastics.
- It is therefore an object of the present invention to provide plastic-like materials having a reduced content of petroleum derivatives.
- It is further an object of the present invention to provide plastic-like materials having chemical properties, such as fire retardancy and smoke suppression, superior to conventional plastics.
- It is also an object of the present invention to provide materials having a reduced content of petroleum derivatives which are economically viable or superior alternatives to conventional plastics.
- In accordance with the foregoing objectives and others, the present invention provides plastic-like materials having interesting physical and mechanical properties, chemical properties such as fire retardancy and smoke suppression superior to conventional plastics, and diminished petroleum-derived material content as compared to conventional plastics.
- It has surprisingly been found that plastic-like materials comprising between about 20 to about 80% by weight of an inorganic salt can be obtained which have physical, mechanical, and chemical properties that are useful for many of the applications in which conventional plastics are employed. Some properties, such as fire retardancy, smoke suppression, toxicity of smoke release, and heat resistance are substantially improved as compared to conventional plastics. Importantly, the plastic-like materials or the invention are cheaper to produce than conventional plastics.
- In one aspect of the present invention a plastic-like composition is provided comprising about 10% to about 80% by weight of a plastic polymer and about 20% to about 80% by weight of an inorganic salt in particulate form. In an interesting aspect of the invention, the weight percentage of inorganic salt is above 50% and tends toward the upper limit of the given range. The composition has a reduced propensity to ignite or smoke in the presence of heat or flame as compared to the thermoplastic polymer which it comprises. The polymer may be either a thermoplastic polymer or a thermosetting polymer. In one embodiment the plastic is a thermosetting plastic such as, for example, an epoxy resin. In another embodiment, the plastic polymer is a thermoplastic polymer such as, for example, a polyvinyl, polyacrylate, polyurethane, polycarbonate, polyester, polyamide, or polyolefin polymer, or any combination thereof. The inorganic salt according to one embodiment is a salt of phosphoric acid or sulfuric acid and in particular an ammonium salt of those acids. In another aspect of the invention, the inorganic salt is provided having a relatively small particle size, such as, for example between about 0.001 μm to about 1,000 μm. Within this range, it has been found to be desirable to provide inorganic salts with particle sizes tending toward the lower limit.
- These and other aspects of the invention will be better understood by reference to the following detailed description of the invention.
- Unless expressly defined otherwise herein, all terms are intended to have their ordinary meaning in the art. As used herein, the term “plastic-like” refers to a material which comprises less polymeric material than conventional plastics but is nonetheless capable of being molded or formed with the application of heat or pressure in the same manner as a conventional plastic material. The “plastic-like” materials of the present invention share many of the physical and mechanical properties of conventional plastics, i.e., they may be shaped using any of the conventional techniques useful for shaping conventional plastics, including for example, injection molding and rolling. However, the plastic-like compositions of the invention comprise far less polymeric material than conventional plastics.
- The term “particulate form” is mean to expansively include any form of solid ammonium sulfate including but not limited to, crystalline particles, microcrystalline particles, micronized particles, nanoparticles, amorphous particles, and the like. The term “thermoplastic” is meant to have its ordinary meaning in the art and generally refers to plastics which are capable of repeatedly softening when heated and hardening when cooled. The term “thermosetting” is also meant to have its ordinary meaning in the art and generally refers to plastics which cannot be re-melted after being formed.
- In the broadest embodiment of the invention, the plastic-like composition comprises about 10% to about 80% by weight of a plastic polymer and about 20% to about 80% by weight of an inorganic salt in particulate form. The composition has a reduced propensity to ignite or smoke in the presence of heat or flame as compared to the plastic polymer, alone. In certain embodiments, the composition is non-flammable when subjected to flame testing, such as U.S. Government standard for flammability resistance FAR 25.853(b).
- An essential component of the composition is a plastic polymer. The plastic polymeric component of the present invention may be any plastic (i.e., a thermoplastic or a thermosetting). In one embodiment, the plastic is a thermoplastic polymer. With due regard to the typical commercial thermoplastic polymers, particular mention may be made, without intending to limit the invention, to acrylics, such as polymethyl methacrylate (PMMA), acryl-nitrite butadiene styrene (ABS), high density polyethylene (HDPE), low density polyethylene (LDPE), polycarbonates, polyesters, including polybutylene terephthalate (PBT) and polyethylene terephthalate (PET), polyamides, such as nylon, polyolefins, including but not limited to polyethylene and polypropylene, polyorganosiloxane rubber, polytetrafluoroethylene (PTFE), polystyrene (PS), silicone polymers and copolymers, styrene-acrylonitrile (SAN), vinyl plastics, including but not limited to vinyl acetate, polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), and polymers and copolymers of vinyl alcohol (VOH), polyurethanes, and polyvinylidene chloride (PVDC). Cellulosics, polyamideimide (PAI), polyarylate (PAR), polyetherimide (PEI), poly(phenylene sulfide) (PPS), polysulfone, polyethersulfone (PES), polyurea, polyetherketone (PEK), and polyetheretherketone (PEEK) are also contemplated to be useful in the practice of the invention.
- Particularly interesting thermoplastic polymers are those formed by polymerization of vinyl monomers, including, but not limited to olefinic monomers such as, for example, ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene, wherein the alkyl substituents may be either linear or branched or may be cycloalkyl constituents. Vinyl aromatic monomers such as styrene and other aryl or hetero-aryl substituted vinyl monomers are also suitable. Exemplary styrenic monomers include styrene, α-methylstyrene, p-tertiary butylstyrene, p-methylstyrene, o-methylstyrene, m-methylstyrene, 2,4-dimethylstyrene, ethylstyrene, α-methyl-p-methyl styrene, bromostyrene, and the like.
- Specific examples of homopolymers and copolymers of olefinic monomers are disclosed in U.S. Pat. No. 6,890,991 to Fujimoto et al, the disclosure of which is hereby incorporated by reference, and include low density polyethylene, ultra-low-density polyethylene, ultra-super-low density polyethylene, linear low density polyethylene, high density polyethylene, ultrahigh molecular weight polyethylene, polypropylene, ethylene-propylene copolymer, polymethylpentene, polybutene, and the like.
- The vinyl monomers may also be vinyl halides. Desirable halogen substituents are chlorine, bromine, fluorine or combinations thereof. A preferred halogen is chlorine as in the case of the vinyl chloride monomer. In that regard, polyvinyl chloride (“PVC”) is a particularly notable plastic for use in the present invention. Other halogenated monomers include without limitation vinylidene chloride, tetrafluoroethylene, chlorotrifluoroethylene, and hexafluoropropylene.
- It will be understood that the term “vinyl plastic” includes homopolymers and copolymers of vinyl monomers. The term “PVC” is meant to include homopolymers of vinyl chloride as well as copolymers of vinyl chloride containing up to about 20% by weight of other monovinylidene compounds copolymerizable therewith, including but not limited to vinyl esters, such as vinyl acetate, vinylidene chloride, and alkyl esters of unsaturated mono- or dicarboxylic acids such as acrylic acid, methacrylic acid, maleic acid and fumaric acid, including vinyl acetate, acrylate esters, and methacrylate esters, and olefins such as ethylene and propylene, and the like.
- Other suitable monomers for use in the thermoplastic polymers of the invention include, but are not limited to, those disclosed in U.S. Pat. No. 6,875,832 to White et al., the disclosure of which is hereby incorporated by reference, namely allylic monomers, (meth)acrylic acid, (meth)acrylates, (meth)acrylamide, N- and N,N-disubstituted (meth)acrylamides, vinyl esters of carboxylic acids and mixtures thereof.
- The thermoplastic polymer of the invention may be a thermoplastic acrylic polymer or copolymer such as describe in, for example, U.S. Pat. No. 4,473,679 to Falk et al and 4,452,941 to Kishida et al., the disclosures of which are hereby incorporated by reference. Special mention may be made of the acrylate monomers disclosed in U.S. Pat. No. 6,875,832 which include, without limitation, C1-C20 alkyl (meth)acrylates (including linear or branched alkyls and cycloalkyls) which include, but are not limited to, methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, iso-butyl (meth)acrylate, tert-butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, isobornyl (meth)acrylate, cyclohexyl (meth)acrylate, 3,3,5-trimethylcyclohexyl (meth)acrylate and isocane (meth)acrylate; oxirane functional (meth)acrylates which include, but are not limited to, glycidyl (meth)acrylate, 3,4-epoxycyclohexylmethyl(meth)acrylate, and 2-(3,4-epoxycyclohexyl)ethyl(meth)acrylate; hydroxy alkyl (meth)acrylates having from 2 to 4 carbon atoms in the alkyl group which include, but are not limited to, hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate and hydroxybutyl (meth)acrylate. The residues may each independently be residues of monomers having more than one (meth)acryloyl group, such as (meth)acrylic anhydride, diethyleneglycol bis(meth)acrylate, 4,4′-isopropylidenediphenol bis(meth)acrylate (bisphenol A di(meth)acrylate), alkoxylated 4,4′-isopropylidenediphenol bis(meth)acrylate, trimethylolpropane tris(meth)acrylate and alkoxylated trimethylolpropane tris(meth)acrylate.
- The thermoplastic polymers may also contain maleimide monomers such as maleimide, N-methyl maleimide, N-iso-propyl maleimide, N-butyl maleimide, N-hexyl maleimide, N-octyl maleimide, N-dodecyl maleimide, N-cyclohexyl maleimide, N-phenyl maleimide, N-2-methyl maleimide, N-2,3-dimethyl phenyl maleimide, N-2,4-dimethyl phenyl maleimide, N-2,3-diethyl phenyl maleimide, N-2,4-diethyl phenyl maleimide, N-2,3-dibutyl phenyl maleimide, N-2,4-dibutyl phenyl maleimide, N-2,6-dimethyl phenyl maleimide, N-2,3-dichlorophenyl maleimide, N-2,4-dichlorophenyl maleimide, N-2,3-dibromophenyl maleimide or N-2,4-dibromophenyl maleimide, and the like as disclosed in U.S. Pat. No. 6,855,769 to Su, the disclosure of which is hereby incorporated by reference.
- The thermoplastic polymers may comprise a polyester resin as described in, for example, U.S. Pat. No. 6,890,991 to Fujimoto et al, the disclosure of which is hereby incorporated by reference. Such polyester resins are obtained by the polycondensation reaction of one or more dicarboxylic acids such as, for example, terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid, 4,4′-diphenyldicarboxylic acid, diphenyletherdicarboxylic acid, α,β-bis(4-carboxyphenoxy)ethane, adipic acid, sebacic acid, azelaic acid, decanedicarboxylic acid, dodecanedicarboxylic acid, cyclohexanedicarboxylic acid and dimer acid, or ester-forming derivarives thereof, and one or more glycols such as, for example, ethylene glycol, propylene glycol, butanediol, pentanediol, neopentyl glycol, hexanediol, octanediol, decanediol, cyclohexane dimethanol, hydroquinone, bisphenol A, 2,2-bis(4′-hydroxyethoxyphenyl)propane, xylene glycol, polyethylene ether glycol, polytetrafluoroethylene ether glycol, and aliphatic polyester oligomer having a hydroxyl group at both terminals. The polyester resin may be either a homopolyester or a copolyester. Other exemplary thermoplastic polyesters are disclosed in, for example, U.S. Pat. No. 6,809,151 to Lacroix et al., the disclosure of which is hereby incorporated by reference. Particularly interesting polyesters are polybutylene terephthalate (PBT) and polyethylene terephthalate (PET).
- Suitable thermoplastic polyurethanes materials include those disclosed in U.S. Pat. No. 6,881,856 to Tanaka et al., the disclosure of which is hereby incorporated by reference. As disclosed in that patent, theremoplastic polyurethanes are obtained by reaction of polyethercarbonate diols with a diisocyanate and a chain extender, such as a polyol or polyamine compound, by a polyurethane-producing reaction. The exemplary polyethercarbonate diols, diisocyanates, and chain extenders disclosed in U.S. Pat. No. 6,881,856 are hereby incorporated by reference.
- The thermoplastic polymers of the invention may also comprise thermoplastic polyamides (nylons) such as those disclosed in U.S. Pat. No. 6,870,005 to Lieberman et al., the disclosure of which is hereby incorporated by reference. These thermoplastic polyamides may be prepared by polymerization of, for example, one or more epsilon lactams such as caprolactam, pyrrolidone, lauryllactam and aminoundecanoic lactam, or amino acid, or by condensation of dibasic acids and diamines. Exemplary polyamides include polycaprolactam (nylon 6), polylauryllactam (nylon 12), polyhexamethylenedipamide (nylon 6,6), polyhexamethyleneazelamide (nylon 6,9), polyhexamethylenesebacamide (nylon 6,10), polyhexamethyleneisophthalamide (nylon 6,10), the condensation product of 11-aminoundecanoic acid (nylon 11), polytetramethyleneadipamide (nylon 4,6), polyhexamethyleneazelaamide (nylon 6,9), polyhexamethylenesebacamide (nylon 6,10), polyhexamethylenedodecanediamide (nylon 6,12), and polydodecanemethylenedodecanamide (nylon 12,12). Other suitable nylon resins are disclosed in, for example, U.S. Pat. No. 6,861,470, the disclosure of which is hereby incorporated by reference.
- Thermoplastic polycarbonate plastics are also well known in the art and include, for example, those described in U.S. Pat. No. 5,756,641 to Kuhling et al., the disclosure of which is hereby incorporated by reference. Such polycarbonates are formed by transesterification of aromatic diphenols with carboxylic acid diaryl esters. Exemplary diphenols include, without limitation, 4,4′-dihydroxydiphenyl, 4,4′-dihydroxydiphenyl sulphide, 2,2-bis-(4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dibromo-4-hydroxyphenyl)-propane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, and 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane. Exemplary carboxylic acid diesters include without limitation di-C6-C20-aryl esters, such as the diesters of phenol or of alkyl-substituted phenols. Special mention may be made of diphenyl carbonate or dicresyl carbonate.
- Particularly interesting polymers according to the invention comprise polyvinyls, polyacrylates, polyurethanes, polycarbonates, polyesters, polyamides, polyolefins, and combinations thereof. Polyvinyl and polyolefin polymers are especially interesting polymers according to the invention.
- The foregoing monomers and polymers are provided by way of example only and are not intended to limit the scope of the invention. The skilled artisan will recognize that any of the numerous thermoplastic polymers known in the art are contemplated to be within the scope of the present invention.
- Alternatively, the plastic component may be a thermosetting plastic such as, without limitation, epoxy resin, polyester resin, natural rubbers such as latex, melamine plastics such as Formica®, phenolics such as Bakelite, urea-formaldehyde, and the like.
- The compositions of the present invention also include as an essential component an inorganic salt. While it is contemplated that a wide variety of inorganic salts will be useful in the practice of the invention, it is advantageous to employ a fire extinguishing inorganic salt. Particular mention may be made of inorganic salts of phosphoric acid, metaphosphoric acid, orthophosphoric acid, pyrophosphoric acid, polyphophoric acid, sulfuric acid, and hydrochloric acid. Ammonium salts are especially useful. Accordingly, particularly interesting inorganic salts include but are not limited to ammonium phosphates, such as (NH4)H2PO4 (mono-ammonium phosphate or ammonium phosphate) and (NH4)2HPO4 (di-ammonium phosphate), and ammonium sulfates, including (NH4)2SO4 (ammonium sulfate or di-ammonium sulfate) and (NH4)HSO4 (ammonium hydrogen sulfate or ammonium bisulfate), and (NH4)2Cl. In one interesting embodiment, the inorganic salt comprises ammonium sulfates, especially (NH4)2SO4. Combinations of any of the foregoing inorganic salts are also contemplated to be useful.
- The inorganic salt is in particulate form. While it is contemplated that any size inorganic salt particulate material will be useful in the practice of the invention, preferred materials will have average particle diameters of below about 1 mm. Accordingly, in one embodiment of the invention, the inorganic salt particulate material has an average particle size of about 0.001 μm to about 1,000 μm. In another embodiment, the inorganic salt particulate material has an average particle size of about 0.01 μm to about 300 μm. In particularly interesting embodiments, the particle size of the inorganic salt is between about 0.1 to about 30 μm, 1 and about 10 μm, and about 5 to about 8 μm. Further, the invention embraces embodiments within the range of 0.001 μm to about 1,000 μm wherein the lower and upper limits are increased or decreased by intervals of 5 μm, each such sub-range being an embodiment of the invention.
- The particles size distribution of the inorganic salt particulate material may be selected by any known method in the art, including the use of mesh sieves. The particle sizes which will pass through standard (Tyler or BS-410) mesh sizes are well known in the art. Inorganic salt particulate materials which have an average particle size sufficiently small to pass through any of the standard Tyler mesh sizes are contemplated to be useful in the practice of the present invention. Accordingly, with regard to the standard Tyler mesh sizes, the invention embraces embodiments having particle sizes of less than about 297, 250, 210, 177, 149, 105, 74, 62, 53, 44, 37, 20, 10, and about 5 μm, respectively. Further control over the distribution of particle size is obtainable by passing the material through two sieves of different mesh, as is well known in the art. The skilled artisan will recognize that various permutations of standard mesh sizes can by employed to obtain a variety of particle size ranges, each of which is contemplated to be an embodiment of the invention. Of course, it is also within the skill in the art to employ non-standard mesh sizes to obtain any desired particle sizes which are larger, smaller, or intermediate to those provided by the standard Tyler mesh sizes.
- Methods for mechanically micronizing particulate matter (i.e., crushing, grinding, and milling) are well known in the art as disclosed in, for example, U.S. Pat. No. 6,726,133 to Hahn et al and U.S. Pat. No. 5,732,894 to Sheahan, the disclosures of which is hereby incorporated by reference. Non-mechanical methods for forming micronized and nanoparticulate materials are also well known in the art, as disclosed in, for example, U.S. Pat. No. 5,874,029 to Subramaniam et al., the disclosure of which is hereby incorporated by reference. It is within the skill in the art to provide inorganic salts in particulate form having the particle sizes disclosed herein.
- For example, U.S. Patent Application Pub. No. 2002/0065198 to Highsmith et al., which is incorporated herein by reference, discloses a process for ball milling commercially available ammonium sulfate granules of approximately 1 mm average size to produce micronized ammonium sulfate particles having the particle size profile shown in Table I:
TABLE I Tyler Sieve No. Wt. % Retained 48 Less than 0.1 60 0.3 80 0.4 100 0.3 200 18 230 49 400 19 pan 13 - The compositions of the invention generally comprise the plastic polymer between about 10% and about 80% by weight and comprise the inorganic salt between about 20% to 80% by weight, with the proviso the sum of the weight % of each component not exceed 100%. In variations of this embodiment, the lower limit of the weight ranges of inorganic salt may be at least 26%, 27%, 28%, or at least 29% by weight. The invention also contemplates sub-ranges within the foregoing ranges wherein the lower and/or upper limits are increased or decreased, respectively, by intervals of 5 weight %, each such sub-range being an embodiment of the invention.
- In one embodiment, the compositions comprise the plastic polymer between about 10% and about 60% by weight and comprise the inorganic salt between about 30% to 80% by weight. In another embodiment, the compositions comprise the plastic polymer between about 10% and about 50% by weight and the inorganic salt between about 40% to 80% by weight. In another embodiment, the compositions comprise the plastic polymer between about 10% and about 40% by weight and the inorganic salt between about 50% to 80% by weight. In a further embodiment, the compositions comprise the plastic polymer between about 10% and about 30% by weight and the inorganic salt between about 60% to 80% by weight. In an yet another embodiment, the compositions comprise the plastic polymer between about 10% and about 20% by weight and the inorganic salt between about 70% to 80% by weight. The weight ratio of plastic polymer to inorganic salt is typically in the range of about 1:8 to about 5:1, including embodiments of 1:7 to about 4:1, 1:5 to about 3:1, 1:3 to about 2:1, and 1:2 to about 1:1.
- One variant of the plastic-like compositions of the invention comprises: (a) about 10 to about 80% by weight of a plastic polymer; and (b) about 10 to about 80% by weight of an inorganic salt having an average particle size between about 0.001 and about 300 μm; said composition having a reduced propensity to ignite or smoke in the presence of heat or flame as compared to said plastic polymer alone; with the proviso that when the weight of the inorganic salt component is ammonium sulfate comprising 25% or less by weight of the composition, the plastic-like composition is substantially non-intumescent.
- It is believed that the compositions of the invention comprise a plurality of inorganic salt particles, such as ammonium sulfate in particulate form, having any of the average particle sizes set forth above, held in a homogenous physical unit by a plastic polymeric binder. By “homogenous physical unit” it is meant that the inorganic salt and the plastic are not readily separable from one another. Unlike conventional plastics, in which a polymeric material forms a matrix which constitutes the bulk of the material, the bulk of the compositions of the invention may be provided by the inorganic salt. It is believed that in the present invention, the plastic material serves as a binder to hold the particulate matrix in place and impart flexibility, ductility, and the like, to the compositions.
- The compositions of the invention may comprise additives. When present, additives may comprise between about 0.01% and about 35% by weight of the composition. In one embodiment, the additives comprises about 20% by weight of the composition.
- The additives include all those well known in the art, including but not limited to, intumescent additives, plasticizers, stabilizers, fillers, blending resins, pigments, and additives, as well known to one skilled in the art. Any plasticizer, stabilizer, filler, or other additive known in the art may be used in the present invention. Suitable plasticizer, stabilizer, fillers, and other additives, include but are not limited to, those disclosed in U.S. Pat. No. 6,706,820 to Kumaki, et al., U.S. Pat. No. 5,552,484 to Enomoto, and U.S. Pat. No. 4,042,556 to Yoshinaga, the contents of which are hereby incorporated by reference herein. The plastics may further comprise U.V. stabilizers, colorants, and impact modifiers. Additives including, but not limited to, low flammability oils such as soybean and corn oils, calcium carbonate, calcium stearate, titanium dioxide, paraffin wax, oxidized PE lubricant, phthalate plasticizers, heat stabilizers, impact modifiers, and intumescent additives are particularly notable. The plasticizer 2-ethyl hexyl diphenyl (Santicizer® 141, Ferro Corp.) has been found useful in the practice of the invention. Thinners for processing may also be desirable in some applications.
- If desired, blowing agents such as for example, chlorinated fluorocarbons, HCFCs, butane, isopentane, carbon dioxide, nitrogen, argon, and the like, may also be used to produce foamed products, all in accordance with well known practice in the art. Methods for making foamed plastic are disclosed in, for example, U.S. Pat. Nos. 3,983,296 and 4,120,833 to Purvis, et al., U.S. Pat. No. 4,017,657 to Foley, et al., U.S. Pat. No. 4,042,556 to Yoshinaga, U.S. Pat. Nos. 5,391,585 and 5,324,461 to Grohman, U.S. Pat. No. 5,686,025 to Martin, U.S. Pat. Nos. 5,783,613 and 5,786,399 to Beekman et al., U.S. Pat. Nos. 6,225,365 and 6,225,365 to Zerafati, et al., and S. K. Dey et al. “Inert-Gas Extrusion of Rigid PVC Foam” Journal of Vinyl & Additive Technology, March 1996, Vol. 2, No. 1, the contents of which are hereby incorporated by reference herein.
- The compositions of the invention may be formed in any technique conventional for forming thermoplastics or thermosettings, including, for example, extrusion, injection molding, blow molding, rotomolding, thermoforming, calandering, and compression molding. The materials of the invention may be extruded in the same manner as conventional plastics, as disclosed in, for example, U.S. Pat. No. 6,350,400 to Piotrowski, U.S. Pat. No. 4,322,170 to Papenmeier; U.S. Pat. No. 3,983,186 to Eilers, et al., M. J. Stevens, “Extruder Principals and Operation”, Elsevier Applied Science Publishers, New York, N.Y. (1985), and C. Rauwendaal, “Polymer Extrusion”, Hanser Publishers, New York, N.Y. (1986), the contents of which are hereby incorporated by reference herein. The compositions are suitable for injection molding and the like. The compositions of the invention may also be formed by rolling under heat as is also well known in the art.
- As evident from the foregoing, the compositions of the invention contain far less polymeric material derived from petroleum than conventional plastics. For example, conventional compounded PVC has the makeup given in Table II.
TABLE II Material Weight Percent (based on PVC resin) PVC Resin 100 Impact Modifier 5.0 Heat Stabilizer 0.8 Filler (CaCO3) 10 Calcium Stearate 1.4 Processing Aid 0.8 Oxidized PE Lubricant 0.15 Paraffin Wax 1.2 TiO2 2.0 - As shown in Table III, conventional compounded PVC comprises approximately 83% by weight polyvinyl chloride polymer, which itself comprises 43% by weight petroleum-derived material. Thus, even polymers such as PVC, which is generally considered to be a “low-petroleum” content material, contains 0.36 pounds (or 36% by weight) of polymer derived from petroleum for every pound of compounded PVC. In contrast, Table III provides three exemplary low-petroleum content formulations of the invention. In each case, the compounded PVC resin is mixed with ammonium sulfate and plasticizer in the ratios given.
TABLE III ammonium Compounded Weight % of sulfate Plasticizer PVC petroleum-derived Sample (wt. %) (wt. %) (wt. %) polymeric component 1 60 19 21 7.6 2 55 19 26 9.4 3 50 19 31 11.2 - Based on the foregoing, the benefits of the present invention as applied to high petroleum content plastics, such as, for example, polyethylene and polypropylene, are immediately apparent. The petroleum based content of such plastics can be reduced by at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or 80%, each being considered an embodiment of the invention. It is contemplated that even greater reductions in the petroleum based content of plastic materials are achievable with the present invention.
- The compositions of the invention have a reduced propensity to ignite or smoke in the presence of heat or flame as compared to the plastic binder material alone. This property is believed to arise from the reduced petroleum content of the materials and the fact that flame retardant inorganic salts, such as ammonium sulfate, release inert gases (i.e., N2) upon decomposition with heat. Accordingly, in particularly desirable embodiments, the inorganic salt is a flame retardant inorganic salt. The compositions of the invention are substantially non-intumescent, in the absence of added intumescent material. This does not preclude, however, the addition of minor amounts of intumescent additives such as intumescent catalysts, carbonifics, and/or blowing agents to the compositions.
- Approximately 20 pounds of ammonium sulfate and approximately 15 pounds of glass balls with sizes ranging from 0.5 to 1 inches were placed in a standard cement mixer. The ammonium sulfate was ground for about four hours. The material was then passed through a 500 Tyler mesh screen. Substantially all of the material passed through the screen indicating that the maximum particle size was about 25 μm. This material was used to make the materials described in the following examples.
- Approximately 60 gm of micronized ammonium sulfate from Example 1 was mixed with approximately 21 gm of a standard compounded PVC (see Table II) and approximately 19 gm pounds of the 2-ethyl hexyl diphenyl plasticizer Santicizer® 141 (Ferro Corp.). The mixture was formed into sheets having a thickness of about 30 mil with twin rollers operating at 380° F. for about five minutes, or until homogeneous.
- Approximately 55 gm pounds of micronized ammonium sulfate from Example 1 was mixed with approximately 26 gm pounds of a standard compounded PVC (see Table II) and approximately 19 gm pounds of the 2-ethyl hexyl diphenyl plasticizer Santicizer® 141 (Ferro Corp.). The mixture was formed into sheets having a thickness of about 30 mil with twin rollers operating at 380° F. for about five minutes, or until homogeneous.
- This material was tested for fire retardancy by an independent laboratory with the Underwriters Laboratories (“UL”) flame test designated UL-94. The material received the highest UL-94 rating of V-0.
- The material also passed the U.S. Government standard for flammability resistance FAR 25.853. That test involves subjecting a panel to edge burning by a flame maintained at 1550° F. for a period of 60 seconds and requires that the material be self-extinguishing before 15 seconds and that it be non-dripping. After subjecting the material to flame for 60 seconds, there was no flaming or dripping of the material.
- Approximately 50 gm of micronized ammonium sulfate from Example 1 was mixed with approximately 31 gm of a standard compounded PVC (see Table II) and approximately 19 gm pounds of the 2-ethyl hexyl diphenyl plasticizer Santicizer® 141 (Ferro Corp.). The mixture was formed into sheets having a thickness of about 30 mil with twin rollers operating at 380° F. for about five minutes, or until homogeneous.
- Approximately 35 gm of micronized ammonium sulfate from Example 1 was mixed with approximately 46 gm pounds of a standard compounded PVC (see Table II) and approximately 19 gm pounds of the 2-ethyl hexyl diphenyl plasticizer Santicizer® 141 (Ferro Corp.). The mixture was formed into sheets having a thickness of about 30 mil with twin rollers operating at 380° F. for about five minutes, or until homogeneous.
- The material also passed the U.S. Government standard for flammability resistance FAR 25.853(b). That test involves subjecting a panel to edge burning by a flame maintained at 1550° F. for a period of 12 seconds and requires that the material be self-extinguishing before 15 seconds and that it be non-dripping. After subjecting the material to flame for 12 seconds, there was no flaming or dripping of the material.
- This example provides a material according to the invention wherein the polymeric binder is a thermosetting polymer. 48 parts of polyester resin 48 (approximately 4 pounds) was mixed with 52 parts (approximately 4.5 pounds) ammonium sulfate from Example 1 in one gallon container. The composition was mixed until homogenous, about 5 minutes, with a drill blade. After mixing, about 900 drops of a methyl ethyl ketone peroxide (MEKP) hardener was added to set the material.
- A 24 feet, 30 mil thick coating of this material was subjected to ASTM E-84 flame spread and smoke evolution testing. The flame spread index was 15 and smoke index was 45. There was no evidence of progressive combustion after 30 minutes. Thus, the material passed ASTM E-84 with a Class A rating.
- It will be understood that the recitation of ranges contained herein are as a matter of convenience only and the inventors are in possession of every value intermediate within the ranges. That is, every intermediate value or sub-range within a disclosed range should be understood to be inherently disclosed.
- The invention having been described by the foregoing description of the preferred embodiments, it will be understood that the skilled artisan may make modifications and variations of these embodiments without departing from the spirit or scope of the invention as set forth in the following claims.
Claims (69)
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CA2614175A1 (en) | 2007-01-11 |
AU2006265673A1 (en) | 2007-01-11 |
US9080037B2 (en) | 2015-07-14 |
US20200157315A1 (en) | 2020-05-21 |
US20180208747A1 (en) | 2018-07-26 |
US20120214915A1 (en) | 2012-08-23 |
US20200157316A1 (en) | 2020-05-21 |
EP1907463A2 (en) | 2008-04-09 |
EP1907463A4 (en) | 2009-12-30 |
WO2007005783A2 (en) | 2007-01-11 |
US20150267040A1 (en) | 2015-09-24 |
WO2007005783A3 (en) | 2007-11-08 |
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