US20070149675A1 - Organic polymer/inorganic particles composite materials - Google Patents
Organic polymer/inorganic particles composite materials Download PDFInfo
- Publication number
- US20070149675A1 US20070149675A1 US11/410,913 US41091306A US2007149675A1 US 20070149675 A1 US20070149675 A1 US 20070149675A1 US 41091306 A US41091306 A US 41091306A US 2007149675 A1 US2007149675 A1 US 2007149675A1
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- US
- United States
- Prior art keywords
- inorganic particles
- organic polymer
- composite material
- minutes
- particles composite
- 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.)
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- 239000010954 inorganic particle Substances 0.000 title claims abstract description 57
- 239000002131 composite material Substances 0.000 title claims abstract description 41
- 229920000620 organic polymer Polymers 0.000 title claims description 36
- 125000000524 functional group Chemical group 0.000 claims abstract description 20
- 238000012986 modification Methods 0.000 claims abstract description 5
- 230000004048 modification Effects 0.000 claims abstract description 5
- 229910021502 aluminium hydroxide Inorganic materials 0.000 claims description 14
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 claims description 14
- 229910001679 gibbsite Inorganic materials 0.000 claims description 14
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 13
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 13
- 229910052681 coesite Inorganic materials 0.000 claims description 7
- 229910052906 cristobalite Inorganic materials 0.000 claims description 7
- 239000000377 silicon dioxide Substances 0.000 claims description 7
- 229910052682 stishovite Inorganic materials 0.000 claims description 7
- 229910052905 tridymite Inorganic materials 0.000 claims description 7
- 229920002635 polyurethane Polymers 0.000 claims description 6
- 239000004814 polyurethane Substances 0.000 claims description 6
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 claims description 5
- 239000000347 magnesium hydroxide Substances 0.000 claims description 5
- 229910001862 magnesium hydroxide Inorganic materials 0.000 claims description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 claims description 3
- 229910000000 metal hydroxide Inorganic materials 0.000 claims description 3
- 150000004692 metal hydroxides Chemical class 0.000 claims description 3
- 150000004767 nitrides Chemical class 0.000 claims description 3
- 150000003839 salts Chemical class 0.000 claims description 3
- 239000004593 Epoxy Substances 0.000 claims description 2
- 239000004642 Polyimide Substances 0.000 claims description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 2
- 125000003700 epoxy group Chemical group 0.000 claims description 2
- 229920000768 polyamine Polymers 0.000 claims description 2
- 229920001721 polyimide Polymers 0.000 claims description 2
- 229920000098 polyolefin Polymers 0.000 claims description 2
- 239000004927 clay Substances 0.000 claims 3
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims 2
- HPTYUNKZVDYXLP-UHFFFAOYSA-N aluminum;trihydroxy(trihydroxysilyloxy)silane;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O[Si](O)(O)O HPTYUNKZVDYXLP-UHFFFAOYSA-N 0.000 claims 1
- VNSBYDPZHCQWNB-UHFFFAOYSA-N calcium;aluminum;dioxido(oxo)silane;sodium;hydrate Chemical compound O.[Na].[Al].[Ca+2].[O-][Si]([O-])=O VNSBYDPZHCQWNB-UHFFFAOYSA-N 0.000 claims 1
- 229910052570 clay Inorganic materials 0.000 claims 1
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 claims 1
- 229910052621 halloysite Inorganic materials 0.000 claims 1
- KWLMIXQRALPRBC-UHFFFAOYSA-L hectorite Chemical compound [Li+].[OH-].[OH-].[Na+].[Mg+2].O1[Si]2([O-])O[Si]1([O-])O[Si]([O-])(O1)O[Si]1([O-])O2 KWLMIXQRALPRBC-UHFFFAOYSA-L 0.000 claims 1
- 229910000271 hectorite Inorganic materials 0.000 claims 1
- 239000010445 mica Substances 0.000 claims 1
- 229910052618 mica group Inorganic materials 0.000 claims 1
- 229910052901 montmorillonite Inorganic materials 0.000 claims 1
- 229910000273 nontronite Inorganic materials 0.000 claims 1
- 229910000275 saponite Inorganic materials 0.000 claims 1
- 229910021647 smectite Inorganic materials 0.000 claims 1
- 239000000454 talc Substances 0.000 claims 1
- 229910052623 talc Inorganic materials 0.000 claims 1
- 229910052902 vermiculite Inorganic materials 0.000 claims 1
- 239000010455 vermiculite Substances 0.000 claims 1
- 235000019354 vermiculite Nutrition 0.000 claims 1
- 230000009970 fire resistant effect Effects 0.000 abstract description 26
- 229920000642 polymer Polymers 0.000 abstract description 18
- 239000000463 material Substances 0.000 abstract description 16
- 239000003063 flame retardant Substances 0.000 abstract description 8
- 238000006243 chemical reaction Methods 0.000 abstract description 5
- 239000011147 inorganic material Substances 0.000 abstract description 4
- 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 abstract description 3
- 230000001681 protective effect Effects 0.000 abstract description 3
- 229910003471 inorganic composite material Inorganic materials 0.000 abstract description 2
- 239000011368 organic material Substances 0.000 abstract description 2
- 238000010438 heat treatment Methods 0.000 description 22
- 239000000203 mixture Substances 0.000 description 20
- 239000004809 Teflon Substances 0.000 description 17
- 229920006362 Teflon® Polymers 0.000 description 17
- 238000007706 flame test Methods 0.000 description 14
- 239000002002 slurry Substances 0.000 description 11
- 230000015572 biosynthetic process Effects 0.000 description 9
- 230000000052 comparative effect Effects 0.000 description 9
- 239000000126 substance Substances 0.000 description 9
- 239000001273 butane Substances 0.000 description 8
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 8
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 8
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- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 6
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 238000003763 carbonization Methods 0.000 description 3
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- 238000000034 method Methods 0.000 description 3
- 229910001845 yogo sapphire Inorganic materials 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- -1 Poly(vinyl alcohol) Polymers 0.000 description 2
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
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- 229910010272 inorganic material Inorganic materials 0.000 description 2
- 239000011976 maleic acid Substances 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 239000002904 solvent Substances 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
- 229920002554 vinyl polymer Polymers 0.000 description 2
- 239000004604 Blowing Agent Substances 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 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
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 125000002573 ethenylidene group Chemical group [*]=C=C([H])[H] 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 229910001629 magnesium chloride Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229910001562 pearlite Inorganic materials 0.000 description 1
- 239000010451 perlite Substances 0.000 description 1
- 235000019362 perlite Nutrition 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
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- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
- H01B3/441—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
- H01B3/447—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from acrylic compounds
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/14—Layer or component removable to expose adhesive
- Y10T428/1405—Capsule or particulate matter containing [e.g., sphere, flake, microballoon, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31547—Of polyisocyanurate
Definitions
- the present invention relates to an organic polymer/inorganic particles composite material showing excellent fire resistant performance under flame sources or fire exposure.
- both of the organic polymer and the inorganic particles contain reactive functional groups.
- Fire resistant or fire retardant materials can be used as the architecture or decorative materials.
- Architecture materials disclosed in TW 583,078 and TW 397,885 primarily comprise a stacked layer, serving as a fire resistant layer, made of nonflammable inorganic materials such as pearlite (or perlite), MgCl 2 , MgO, CaCO 3 or cement.
- a stiff fire resistant laminate can be obtained from flexible substrates made of fibers or nonwovens blended with flame retardants, foaming agents and 50 ⁇ 80? inorganic materials by weight.
- Fire resistant coatings serving as decorative materials, disclosed in TW 442,549, TW 499,469 and TW 419,514 comprise a combination of foaming and intumescent agents, carbonization agents, flame retardants, and adhesives which foam and intumesce under fire exposure.
- U.S. Pat. No. 5,723,515 discloses a fire-retardant coating material including a fluid intumescent base material having a foaming agent, a blowing agent, a charring agent, a binding agent, a solvent, and a pigment, increasing resistance to cracking and shrinking.
- 5,218,027 is manufactured from a composition of a copolymer or terpolymer, a low modulus polymer, and a synthetic hydrocarbon elastomer.
- the fire retardant additive comprising a group I, group II or group III metal hydroxide with the proviso that at least 1% by weight of the composition is in the form of an organopolysiloxane.
- U.S. Pat. No. 6,262,161 relates to filled interpolymer compositions of ethylene and/or alpha-olefin/vinyl or vinylidene monomers, showing improved performance under exposure to flame or ignition sources, and fabricated articles thereof.
- the articles are often in the form of a film, sheet, a multilayered structure, a floor, wall, or ceiling covering, foams, fibers, electrical devices, or wire and cable assemblies.
- the heated area of a the conventional fire resistant material can be carbonized rapidly and expand to 8 ⁇ 10 times in volume greater than original due to the foaming, intumescent, and carbonization agents contained.
- the intumescent carbonization layer or the heated part
- the flame and heat can directly transfer to the interior materials and the fire resistant ability will vanish. Accordingly, an improved fire resistant material is desirable.
- the invention utilizes a fire resistant composite material comprising various inorganic particles well dispersed in a polymer having reactive functional groups.
- the inorganic particles also contain reactive functional groups, originally or after surface modification, so that can react with the corresponding reactive functional groups of the polymer to form organic/inorganic composite materials.
- the organic polymer with reactive functional groups can be polyacid, polyurethane, epoxy, polyolefin, polyamine, polyimide, or derivatives thereof.
- the reactive functional group can be epoxy group, —COOH, —NH 3 , or —NCO.
- the preferred inorganic particles comprise hydroxide, nitride, oxide, or metal salt which can react with the functional groups of the organic polymer.
- the polymer When the composite material is burned or under fire exposure, the polymer forms a char layer and the inorganic particles radiate the absorbed heat.
- the inorganic particles also strengthen the mechanical properties of the structure through the reaction between inorganic and organic materials, so that the formed char layer on the surface is firm and can maintain its structural integrity without peeling off or cracks, effectively preventing direct heat transferring into interior parts.
- the fire resistant material is not only flame retardant but also protective toward the interior materials. As a result, the duration of fire resistant ability is tremendously improved.
- FIG. 3 is a flowchart demonstrating the processes of the organic polymer/inorganic particles composite material. As shown in FIG. 3 , a detailed description is given in the following embodiments with reference to the accompanying drawings.
- FIGS. 1 a ⁇ 1 d are pictures showing conventional intumescent fire resistant materials subjected to a flame test
- FIG. 2 is a picture showing an organic polymer/inorganic particles composite material of the invention which is subjected to a flame test;
- FIG. 3 is a flowchart demonstrating the synthesis processes of the organic polymer/inorganic particles composite material.
- FIG. 4 is a schematic figure demonstrating the flame test for a sample of the organic polymer/inorganic particles composite material.
- the organic polymer containing reactive functional groups (such as R—COOH) on main chains is mixed with solvents (such as water, alcohol, or MEK). Subsequently, inorganic particles with corresponding reactive functional groups (such as M-OH) are added to the polymer solution, and the mixture is stirred at 70 ⁇ 90? for 20 minutes to several hours till the reaction has completed.
- the slurry of R—COO ⁇ M + is produced by means of the reaction between R—COOH of the polymer and M-OH of the inorganic particles, where R represents carbon chains and M represents metal.
- a composite sample layer is obtained by coating the slurry on a teflon sheet followed by drying and molding the slurry layer at elevated temperature.
- the sample layer can be rigid or flexible depending on the organic/inorganic system of the composite.
- Each sample layer of the following embodiments and comparative examples is prepared according to the processes illustrated in FIG. 3 .
- the sample layer is placed on a piece of A4 size paper and subjected to a flame test. Table 1 shows the results of the flame test in different organic/inorganic systems.
- Poly(ethylene-co-acrylic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles Al(OH) 3 with reactive functional groups M-OH were added to the polymer solution, and the mixture was stirred at 70 ⁇ 90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- the sample layer 20 was removed from the teflon sheet (not shown), and placed on a piece of A4 size paper 10 .
- a flame test was conducted on the surface of the sample layer 20 by butane gas torch 30 with flame temperature of 1000 ⁇ 1200? (flame 40 ) for 30 seconds ⁇ 3 minutes.
- the result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. There was no scorch observed on the piece of A4 size paper after heating for 30, 60 and 120 seconds while it became slightly scorched after heating for 180 seconds.
- the duration of fire resistant ability was 3 minutes due to the strengthened sample layer, i.e. R—COOH of poly(ethylene-co-acrylic acid) reacted with M-OH of Al(OH) 3 to form chemical bonds instead of physical blending.
- Poly(ethylene-co-acrylic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles Mg(OH) 2 with reactive functional groups M-OH were added to the polymer solution, and the mixture was stirred at 70 ⁇ 90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- the sample layer 20 was removed from the teflon sheet (not shown), and placed on a piece of A4 size paper 10 .
- a flame test was conducted on the surface of the sample layer 20 by butane gas torch 30 with flame temperature of 1000 ⁇ 1200? (flame 40 ) for 30 seconds ⁇ 3 minutes.
- the result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. There was no scorch observed on the piece of A4 size paper after heating for 30, 60 and 120 seconds while it became slightly scorched after heating for 180 seconds.
- the duration of fire resistant ability was 3 minutes due to the strengthened sample layer, i.e. R—COOH of poly(ethylene-co-acrylic acid) reacted with M-OH of Mg(OH) 2 to form chemical bonds instead of physical blending.
- Poly(acrylic acid-co-maleic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles Al(OH) 3 with reactive functional groups M-OH were added to the polymer solution, and the mixture was stirred at 70 ⁇ 90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- the sample layer 20 was removed from the teflon sheet (not shown), and placed on a piece of A4 size paper 10 .
- a flame test was conducted on the surface of the sample layer 20 by butane gas torch 30 with flame temperature of 1000 ⁇ 1200? (flame 40 ) for 30 seconds ⁇ 3 minutes.
- the result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. There was no scorch observed on the piece of A4 size paper after heating for 30, 60 and 120 seconds while it became slightly scorched after heating for 180 seconds.
- the duration if fire resistant ability was 3 minutes due to the strengthened sample layer, i.e. R—COOH of poly(acrylic acid-co-maleic acid) reacted with M-OH of Al(OH) 3 to form chemical bonds instead of physical blending.
- Polyurethane containing R—NCO was dissolved or dispersed in hexane. Subsequently, inorganic particles Al(OH) 3 with reactive functional groups M-OH were added to the polymer solution, and the mixture was stirred at room temperature for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, molded at 60? for 120 minutes.
- the sample layer 20 was removed from the teflon sheet (not shown), and placed on a piece of A4 size paper 10 .
- a flame test was conducted on the surface of the sample layer 20 by butane gas torch 30 with flame temperature of 1000 ⁇ 1200? (flame 40 ) for 30 seconds ⁇ 3 minutes.
- the result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. There was no scorch observed on the piece of A4 size paper after heating for 30, 60 and 120 seconds while it became slightly scorched after heating for 180 seconds.
- the duration of fire resistant ability was 3 minutes due to the strengthened sample layer, i.e. R—NCO of polyurethane reacted with M-OH of Al(OH) 3 to form chemical bonds instead of physical blending.
- Poly(ethylene-co-acrylic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles SiO 2 were added to the polymer solution, and the mixture was stirred at 70 ⁇ 90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- the sample layer 20 was removed from the teflon sheet (not shown), and placed on a piece of A4 size paper 10 .
- a flame test was conducted on the surface of the sample layer 20 by butane gas torch 30 with flame temperature of 1000 ⁇ 1200? (flame 40 ) for 30 seconds ⁇ 3 minutes.
- the result of the burning phenomenon of the piece of A4 size paper was summarized in table 1.
- the composite When the flame contacted the surface of the sample layer, the composite rapidly melted within several seconds and then charred irregularly in 30 seconds. The nonuniform char had lost its structural integrity due to the formation of cracks.
- a piece of A4 size paper became slightly scorched after heating for 30 seconds; scorched after heating for 60 seconds. Finally, the paper substrate burned after heating for 120 seconds because of the majority of cracks.
- the duration of fire resistant ability is less than 2 minutes because that R—COOH of poly(ethylene-co-acrylic acid) did not react with SiO 2 to form a well-structured composite by the formation of chemical bonds.
- Poly(acrylic acid-co-maleic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles Al 2 O 3 were added to the polymer solution, and the mixture was stirred at 70 ⁇ 90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- the sample layer 20 was removed from the teflon sheet (not shown), and placed on a piece of A4 size paper 10 .
- a flame test was conducted on the surface of the sample layer 20 by butane gas torch 30 with flame temperature of 1000 ⁇ 1200? (flame 40 ) for 30 seconds ⁇ 3 minutes.
- the result of the burning phenomenon of the piece of A4 size paper was summarized in table 1.
- the composite When the flame contacted the surface of the sample layer, the composite rapidly melted within several seconds and then charred irregularly in 30 seconds. The nonuniform char had lost its structural integrity due to the formation of cracks.
- a piece of A4 size paper became slightly scorched after heating for 30 seconds; scorched after heating for 60 seconds. Finally, the paper substrate burned after heating for 120 seconds because of the majority of cracks.
- the duration of fire resistant ability is less than 2 minutes because that R—COOH of poly(acrylic acid-co-maleic acid) did not react with Al 2 O 3 to form a well-structured composite by the formation of chemical bonds.
- Polyurethane containing R—NCO was dissolved or dispersed in hexane. Subsequently, inorganic particles SiO 2 were added to the polymer solution, and the mixture was stirred at room temperature for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, molded at 60? for 120 minutes.
- the sample layer 20 was removed from the teflon sheet (not shown), and placed on a piece of A4 size paper 10 .
- a flame test was conducted on the surface of the sample layer 20 by butane gas torch 30 with flame temperature of 1000 ⁇ 1200? (flame 40 ) for 30 seconds ⁇ 3 minutes.
- the result of the burning phenomenon of the piece of A4 size paper was summarized in table 1.
- the composite When the flame contacted the surface of the sample layer, the composite rapidly melted within several seconds and then charred irregularly in 30 seconds. The nonuniform char had lost its structural integrity due to the formation of cracks.
- a piece of A4 size paper became slightly scorched after heating for 30 to 60 seconds; scorched after heating for 120 seconds. Finally, the paper substrate burned after heating for 180 seconds because of the majority of cracks.
- the duration of fire resistant ability is about 2 minutes because that R—NCO of polyurethane did not react with SiO 2 to form a well-structured composite by the formation of chemical bonds.
- Poly(vinyl alcohol) containing R—OH was dissolved or dispersed in water. Subsequently, inorganic particles Al(OH) 3 were added to the polymer solution, and the mixture was stirred at 70 ⁇ 90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- the sample layer 20 was removed from the teflon sheet (not shown), and placed on a piece of A4 size paper 10 .
- a flame test was conducted on the surface of the sample layer 20 by butane gas torch 30 with flame temperature of 1000 ⁇ 1200? (flame 40 ) for 30 seconds ⁇ 3 minutes.
- the result of the burning phenomenon of the piece of A4 size paper was summarized in table 1.
- the composite When the flame contacted the surface of the sample layer, the composite rapidly melted within several seconds and then charred irregularly in 30 seconds. The nonuniform char had lost its structural integrity due to the formation of cracks.
- a piece of A4 size paper became slightly scorched after heating for 30 seconds; scorched after heating for 60 seconds. Finally, the paper substrate burned after heating for 120 seconds because of the majority of cracks.
- the duration of fire resistant ability is less than 2 minutes because that R—OH of poly(vinyl alcohol) did not react with the M-OH of Al(OH) 3 to form a well-structured composite by the formation of chemical bonds.
- the formed char layer on the surface is firm with excellent structural integrity and does not easily crack and peel off, effectively preventing direct heat transferring into interior parts.
- the fire resistant material is not only flame retardant but also protective toward the interior materials. As a result, the duration of fire resistant ability is tremendously improved.
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Abstract
The invention discloses a fire resistant composite material comprising inorganic particles well dispersed in a polymer having reactive functional groups. The inorganic particles also contain reactive functional groups, originally or after surface modification, that can react with the corresponding reactive functional groups of the polymer to form organic/inorganic composite materials. When the composite material is burned or under fire exposure, the polymer forms a char layer and the inorganic particles radiate absorbed heat. The inorganic particles also strengthen the mechanical properties of the structure through the reaction between inorganic and organic materials, so that the formed char layer is firm and can maintain its structural integrity without peeling off or cracks, effectively preventing direct heat transferring into the interior parts. The fire resistant material is not only flame retardant but also protective toward the interior materials. As a result, the duration of fire resistant ability is tremendously improved.
Description
- 1. Field of the Invention
- The present invention relates to an organic polymer/inorganic particles composite material showing excellent fire resistant performance under flame sources or fire exposure. Within this composite system, both of the organic polymer and the inorganic particles contain reactive functional groups.
- 2. Description of the Related Art
- Fire resistant or fire retardant materials can be used as the architecture or decorative materials. Architecture materials disclosed in TW 583,078 and TW 397,885 primarily comprise a stacked layer, serving as a fire resistant layer, made of nonflammable inorganic materials such as pearlite (or perlite), MgCl2, MgO, CaCO3 or cement. In addition, a stiff fire resistant laminate can be obtained from flexible substrates made of fibers or nonwovens blended with flame retardants, foaming agents and 50˜80? inorganic materials by weight.
- Fire resistant coatings, serving as decorative materials, disclosed in TW 442,549, TW 499,469 and TW 419,514 comprise a combination of foaming and intumescent agents, carbonization agents, flame retardants, and adhesives which foam and intumesce under fire exposure. U.S. Pat. No. 5,723,515 discloses a fire-retardant coating material including a fluid intumescent base material having a foaming agent, a blowing agent, a charring agent, a binding agent, a solvent, and a pigment, increasing resistance to cracking and shrinking. A compound disclosed by U.S. Pat. No. 5,218,027 is manufactured from a composition of a copolymer or terpolymer, a low modulus polymer, and a synthetic hydrocarbon elastomer. The fire retardant additive comprising a group I, group II or group III metal hydroxide with the proviso that at least 1% by weight of the composition is in the form of an organopolysiloxane. U.S. Pat. No. 6,262,161 relates to filled interpolymer compositions of ethylene and/or alpha-olefin/vinyl or vinylidene monomers, showing improved performance under exposure to flame or ignition sources, and fabricated articles thereof. The articles are often in the form of a film, sheet, a multilayered structure, a floor, wall, or ceiling covering, foams, fibers, electrical devices, or wire and cable assemblies.
- Specifically, as shown in
FIGS. 1 a˜1 b, the heated area of a the conventional fire resistant material can be carbonized rapidly and expand to 8˜10 times in volume greater than original due to the foaming, intumescent, and carbonization agents contained. However, as shown inFIGS. 1 c˜1 d, after long term heating, the intumescent carbonization layer (or the heated part) will slightly crack and peel off, therefore the flame and heat can directly transfer to the interior materials and the fire resistant ability will vanish. Accordingly, an improved fire resistant material is desirable. - In view of the problems in the related art, the invention utilizes a fire resistant composite material comprising various inorganic particles well dispersed in a polymer having reactive functional groups. The inorganic particles also contain reactive functional groups, originally or after surface modification, so that can react with the corresponding reactive functional groups of the polymer to form organic/inorganic composite materials. Through the reaction between organic and inorganic components, the mechanical and fire resistant properties of the organic polymer are strengthened and enhanced. The organic polymer with reactive functional groups can be polyacid, polyurethane, epoxy, polyolefin, polyamine, polyimide, or derivatives thereof. The reactive functional group can be epoxy group, —COOH, —NH3, or —NCO. The preferred inorganic particles comprise hydroxide, nitride, oxide, or metal salt which can react with the functional groups of the organic polymer.
- When the composite material is burned or under fire exposure, the polymer forms a char layer and the inorganic particles radiate the absorbed heat. The inorganic particles also strengthen the mechanical properties of the structure through the reaction between inorganic and organic materials, so that the formed char layer on the surface is firm and can maintain its structural integrity without peeling off or cracks, effectively preventing direct heat transferring into interior parts. The fire resistant material is not only flame retardant but also protective toward the interior materials. As a result, the duration of fire resistant ability is tremendously improved.
-
FIG. 3 is a flowchart demonstrating the processes of the organic polymer/inorganic particles composite material. As shown inFIG. 3 , a detailed description is given in the following embodiments with reference to the accompanying drawings. - The present invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
-
FIGS. 1 a˜1 d are pictures showing conventional intumescent fire resistant materials subjected to a flame test; -
FIG. 2 is a picture showing an organic polymer/inorganic particles composite material of the invention which is subjected to a flame test; -
FIG. 3 is a flowchart demonstrating the synthesis processes of the organic polymer/inorganic particles composite material; and -
FIG. 4 is a schematic figure demonstrating the flame test for a sample of the organic polymer/inorganic particles composite material. - The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
- The organic polymer containing reactive functional groups (such as R—COOH) on main chains is mixed with solvents (such as water, alcohol, or MEK). Subsequently, inorganic particles with corresponding reactive functional groups (such as M-OH) are added to the polymer solution, and the mixture is stirred at 70˜90? for 20 minutes to several hours till the reaction has completed. The slurry of R—COO−M+ is produced by means of the reaction between R—COOH of the polymer and M-OH of the inorganic particles, where R represents carbon chains and M represents metal. A composite sample layer is obtained by coating the slurry on a teflon sheet followed by drying and molding the slurry layer at elevated temperature. The sample layer can be rigid or flexible depending on the organic/inorganic system of the composite. Each sample layer of the following embodiments and comparative examples is prepared according to the processes illustrated in
FIG. 3 . Finally, the sample layer is placed on a piece of A4 size paper and subjected to a flame test. Table 1 shows the results of the flame test in different organic/inorganic systems. - Poly(ethylene-co-acrylic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles Al(OH)3 with reactive functional groups M-OH were added to the polymer solution, and the mixture was stirred at 70˜90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- As shown in
FIG. 4 , thesample layer 20 was removed from the teflon sheet (not shown), and placed on a piece ofA4 size paper 10. A flame test was conducted on the surface of thesample layer 20 bybutane gas torch 30 with flame temperature of 1000˜1200? (flame 40) for 30 seconds˜3 minutes. The result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. There was no scorch observed on the piece of A4 size paper after heating for 30, 60 and 120 seconds while it became slightly scorched after heating for 180 seconds. - According to this embodiment, the duration of fire resistant ability was 3 minutes due to the strengthened sample layer, i.e. R—COOH of poly(ethylene-co-acrylic acid) reacted with M-OH of Al(OH)3 to form chemical bonds instead of physical blending.
- Poly(ethylene-co-acrylic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles Mg(OH)2 with reactive functional groups M-OH were added to the polymer solution, and the mixture was stirred at 70˜90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- As shown in
FIG. 4 , thesample layer 20 was removed from the teflon sheet (not shown), and placed on a piece ofA4 size paper 10. A flame test was conducted on the surface of thesample layer 20 bybutane gas torch 30 with flame temperature of 1000˜1200? (flame 40) for 30 seconds˜3 minutes. The result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. There was no scorch observed on the piece of A4 size paper after heating for 30, 60 and 120 seconds while it became slightly scorched after heating for 180 seconds. - According to this embodiment, the duration of fire resistant ability was 3 minutes due to the strengthened sample layer, i.e. R—COOH of poly(ethylene-co-acrylic acid) reacted with M-OH of Mg(OH)2 to form chemical bonds instead of physical blending.
- Poly(acrylic acid-co-maleic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles Al(OH)3 with reactive functional groups M-OH were added to the polymer solution, and the mixture was stirred at 70˜90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- As shown in
FIG. 4 , thesample layer 20 was removed from the teflon sheet (not shown), and placed on a piece ofA4 size paper 10. A flame test was conducted on the surface of thesample layer 20 bybutane gas torch 30 with flame temperature of 1000˜1200? (flame 40) for 30 seconds˜3 minutes. The result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. There was no scorch observed on the piece of A4 size paper after heating for 30, 60 and 120 seconds while it became slightly scorched after heating for 180 seconds. - According to this embodiment, the duration if fire resistant ability was 3 minutes due to the strengthened sample layer, i.e. R—COOH of poly(acrylic acid-co-maleic acid) reacted with M-OH of Al(OH)3 to form chemical bonds instead of physical blending.
- Polyurethane containing R—NCO was dissolved or dispersed in hexane. Subsequently, inorganic particles Al(OH)3 with reactive functional groups M-OH were added to the polymer solution, and the mixture was stirred at room temperature for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, molded at 60? for 120 minutes.
- As shown in
FIG. 4 , thesample layer 20 was removed from the teflon sheet (not shown), and placed on a piece ofA4 size paper 10. A flame test was conducted on the surface of thesample layer 20 bybutane gas torch 30 with flame temperature of 1000˜1200? (flame 40) for 30 seconds˜3 minutes. The result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. There was no scorch observed on the piece of A4 size paper after heating for 30, 60 and 120 seconds while it became slightly scorched after heating for 180 seconds. - According to this embodiment, the duration of fire resistant ability was 3 minutes due to the strengthened sample layer, i.e. R—NCO of polyurethane reacted with M-OH of Al(OH)3 to form chemical bonds instead of physical blending.
- Poly(ethylene-co-acrylic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles SiO2 were added to the polymer solution, and the mixture was stirred at 70˜90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- As shown in
FIG. 4 , thesample layer 20 was removed from the teflon sheet (not shown), and placed on a piece ofA4 size paper 10. A flame test was conducted on the surface of thesample layer 20 bybutane gas torch 30 with flame temperature of 1000˜1200? (flame 40) for 30 seconds˜3 minutes. The result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. When the flame contacted the surface of the sample layer, the composite rapidly melted within several seconds and then charred irregularly in 30 seconds. The nonuniform char had lost its structural integrity due to the formation of cracks. A piece of A4 size paper became slightly scorched after heating for 30 seconds; scorched after heating for 60 seconds. Finally, the paper substrate burned after heating for 120 seconds because of the majority of cracks. - According to this comparative example, the duration of fire resistant ability is less than 2 minutes because that R—COOH of poly(ethylene-co-acrylic acid) did not react with SiO2 to form a well-structured composite by the formation of chemical bonds.
- Poly(acrylic acid-co-maleic acid) containing R—COOH was dissolved or dispersed in water. Subsequently, inorganic particles Al2O3 were added to the polymer solution, and the mixture was stirred at 70˜90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- As shown in
FIG. 4 , thesample layer 20 was removed from the teflon sheet (not shown), and placed on a piece ofA4 size paper 10. A flame test was conducted on the surface of thesample layer 20 bybutane gas torch 30 with flame temperature of 1000˜1200? (flame 40) for 30 seconds˜3 minutes. The result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. When the flame contacted the surface of the sample layer, the composite rapidly melted within several seconds and then charred irregularly in 30 seconds. The nonuniform char had lost its structural integrity due to the formation of cracks. A piece of A4 size paper became slightly scorched after heating for 30 seconds; scorched after heating for 60 seconds. Finally, the paper substrate burned after heating for 120 seconds because of the majority of cracks. - According to this comparative example, the duration of fire resistant ability is less than 2 minutes because that R—COOH of poly(acrylic acid-co-maleic acid) did not react with Al2O3 to form a well-structured composite by the formation of chemical bonds.
- Polyurethane containing R—NCO was dissolved or dispersed in hexane. Subsequently, inorganic particles SiO2 were added to the polymer solution, and the mixture was stirred at room temperature for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, molded at 60? for 120 minutes.
- As shown in
FIG. 4 , thesample layer 20 was removed from the teflon sheet (not shown), and placed on a piece ofA4 size paper 10. A flame test was conducted on the surface of thesample layer 20 bybutane gas torch 30 with flame temperature of 1000˜1200? (flame 40) for 30 seconds˜3 minutes. The result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. When the flame contacted the surface of the sample layer, the composite rapidly melted within several seconds and then charred irregularly in 30 seconds. The nonuniform char had lost its structural integrity due to the formation of cracks. A piece of A4 size paper became slightly scorched after heating for 30 to 60 seconds; scorched after heating for 120 seconds. Finally, the paper substrate burned after heating for 180 seconds because of the majority of cracks. - According to this comparative example, the duration of fire resistant ability is about 2 minutes because that R—NCO of polyurethane did not react with SiO2 to form a well-structured composite by the formation of chemical bonds.
- Poly(vinyl alcohol) containing R—OH was dissolved or dispersed in water. Subsequently, inorganic particles Al(OH)3 were added to the polymer solution, and the mixture was stirred at 70˜90 for 20 minutes. 1 mm-thick mixture slurry was coated on a teflon sheet, and then placed in an oven, dried at 60? for 60 minutes, 80? for 60 minutes, 100? for 60 minutes, 120? for 30 minutes, 140? for 30 minutes, 160? for 30 minutes, 180? for 30 minutes, and finally, molded at 200? for 240 minutes.
- As shown in
FIG. 4 , thesample layer 20 was removed from the teflon sheet (not shown), and placed on a piece ofA4 size paper 10. A flame test was conducted on the surface of thesample layer 20 bybutane gas torch 30 with flame temperature of 1000˜1200? (flame 40) for 30 seconds˜3 minutes. The result of the burning phenomenon of the piece of A4 size paper was summarized in table 1. When the flame contacted the surface of the sample layer, the composite rapidly melted within several seconds and then charred irregularly in 30 seconds. The nonuniform char had lost its structural integrity due to the formation of cracks. A piece of A4 size paper became slightly scorched after heating for 30 seconds; scorched after heating for 60 seconds. Finally, the paper substrate burned after heating for 120 seconds because of the majority of cracks. - According to this comparative example, the duration of fire resistant ability is less than 2 minutes because that R—OH of poly(vinyl alcohol) did not react with the M-OH of Al(OH)3 to form a well-structured composite by the formation of chemical bonds.
- Due to the chemical bonding between the corresponding reactive functional groups of the organic polymer and the inorganic particles, the formed char layer on the surface is firm with excellent structural integrity and does not easily crack and peel off, effectively preventing direct heat transferring into interior parts. The fire resistant material is not only flame retardant but also protective toward the interior materials. As a result, the duration of fire resistant ability is tremendously improved.
- While the invention has been described by ways of examples and in terms of the preferred embodiments, it can be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
TABLE 1 Results of the flame test of the organic polymer/inorganic particles composite materials Paper states after direct heating Organic Inorganic at 1000-1200° C. for polymer particles 30 secs. 1 min. 2 mins. 3 mins. poly Al(OH)3 unchanged unchanged unchanged Slightly (ethylene- scorched co-acrylic acid) poly Mg(OH)2 unchanged unchanged unchanged Slightly (ethylene- scorched co-acrylic acid) poly SiO2 Slightly Scorched burning — (ethylene- scorched co-acrylic acid) poly Al(OH)3 unchanged unchanged unchanged Slightly (acrylic scorched acid-co- maleic acid) poly Al2O3 Slightly Scorched burning — (acrylic scorched acid-co- maleic acid) polyure- Al(OH)3 unchanged unchanged unchanged Slightly thane scorched polyure- SiO2 Slightly Slightly Scorched burning thane scorched scorched poly Al(OH)3 Slightly Scorched burning — vinyl scorched alcohol
Claims (19)
1. An organic polymer/inorganic particles composite material, comprising:
an organic polymer with a first reactive functional group; and
inorganic particles, wherein the inorganic particles contains a second reactive functional group originally or after surface modification.
2. The organic polymer/inorganic particles composite material as claimed in claim 1 , wherein the content of the organic polymer is between 10˜90? by weight.
3. The organic polymer/inorganic particles composite material as claimed in claim 2 , wherein the first reactive functional group comprises epoxy group, —COOH, —NH3, or —NCO.
4. The organic polymer/inorganic particles composite material as claimed in claim 2 , wherein the organic polymer comprises polyacid, polyurethane, epoxy, polyolefin, polyamine, polyimide, or derivatives thereof.
5. The organic polymer/inorganic particles composite material as claimed in claim 1 , wherein the content of the inorganic particles is between 10˜90? by weight.
6. The organic polymer/inorganic particles composite material as claimed in claim 5 , wherein the inorganic particles comprise hydroxide, nitride, oxide, or metal salt.
7. The organic polymer/inorganic particles composite material as claimed in claim 6 , wherein the hydroxide comprises metal hydroxide.
8. The organic polymer/inorganic particles composite material as claimed in claim 7 , wherein the metal hydroxide comprises Al(OH)3 or Mg(OH)2.
9. The organic polymer/inorganic particles composite material as claimed in claim 6 , wherein the oxide comprises SiO2, TiO2, or ZnO.
10. The organic polymer/inorganic particles composite material as claimed in claim 6 , wherein the nitride comprises BN.
11. The organic polymer/inorganic particles composite material as claimed in claim 6 , wherein the metal salt comprises CaCO3.
12. The organic polymer/inorganic particles composite material as claimed in claim 5 , wherein the inorganic particles comprise clay.
13. The organic polymer/inorganic particles composite material as claimed in claim 12 , wherein the clay comprises smectite clay, vermiculite, halloysite, sericite, saponite, montmorillonite, beidellite, nontronite, mica, or hectorite.
14. The organic polymer/inorganic particles composite material as claimed in claim 5 , wherein the inorganic particles comprise SiC.
15. The organic polymer/inorganic particles composite material as claimed in claim 5 , wherein the inorganic particles comprise LDH.
16. The organic polymer/inorganic particles composite material as claimed in claim 5 , wherein the inorganic particles comprise talc.
17. The organic polymer/inorganic particles composite material as claimed in claim 3 , wherein the inorganic particles comprise Al(OH)3 or Mg(OH)2.
18. The organic polymer/inorganic particles composite material as claimed in claim 17 , wherein the content of the organic polymer is between 10˜90? by weight.
19. The organic polymer/inorganic particles composite material as claimed in claim 17 , wherein the content of the inorganic particles is between 10˜90? by weight.
Priority Applications (6)
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US11/642,646 US8330045B2 (en) | 2005-12-26 | 2006-12-21 | Fire-resistant wire/cable |
US11/642,634 US8329820B2 (en) | 2005-12-26 | 2006-12-21 | Fire-resistant coating material |
US11/642,627 US8329819B2 (en) | 2005-12-26 | 2006-12-21 | Organic/inorganic composite and fire-resistant plate utilizing the same |
US11/984,174 US7875564B2 (en) | 2005-12-26 | 2007-11-14 | Multilayer fire-resistant material |
US11/954,542 US8013037B2 (en) | 2006-04-26 | 2007-12-12 | Fire resistant material and formation thereof |
US13/196,522 US8173724B2 (en) | 2005-12-26 | 2011-08-02 | Fire resistant material and formulation thereof |
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TW94146503 | 2005-12-26 |
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US11/642,627 Continuation-In-Part US8329819B2 (en) | 2005-12-26 | 2006-12-21 | Organic/inorganic composite and fire-resistant plate utilizing the same |
US11/642,634 Continuation-In-Part US8329820B2 (en) | 2005-12-26 | 2006-12-21 | Fire-resistant coating material |
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US11/642,627 Active 2027-06-12 US8329819B2 (en) | 2005-12-26 | 2006-12-21 | Organic/inorganic composite and fire-resistant plate utilizing the same |
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US11/642,627 Active 2027-06-12 US8329819B2 (en) | 2005-12-26 | 2006-12-21 | Organic/inorganic composite and fire-resistant plate utilizing the same |
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US (3) | US20070149675A1 (en) |
JP (3) | JP4440915B2 (en) |
DE (3) | DE102006062146B4 (en) |
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- 2006-12-21 US US11/642,627 patent/US8329819B2/en active Active
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- 2006-12-22 DE DE102006062146.8A patent/DE102006062146B4/en active Active
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- 2006-12-22 DE DE200610062147 patent/DE102006062147A1/en not_active Withdrawn
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Also Published As
Publication number | Publication date |
---|---|
TW200725649A (en) | 2007-07-01 |
US8329819B2 (en) | 2012-12-11 |
DE102006062146A1 (en) | 2008-04-03 |
DE102006062148B4 (en) | 2011-09-29 |
GB2433741B (en) | 2010-08-18 |
DE102006062146B4 (en) | 2017-03-30 |
GB2433741A (en) | 2007-07-04 |
JP4440915B2 (en) | 2010-03-24 |
JP2007197704A (en) | 2007-08-09 |
US8329820B2 (en) | 2012-12-11 |
GB2433831A (en) | 2007-07-04 |
TW200724619A (en) | 2007-07-01 |
TWI333496B (en) | 2010-11-21 |
JP5199570B2 (en) | 2013-05-15 |
GB2433742A (en) | 2007-07-04 |
GB2433831B (en) | 2010-09-08 |
US20070149676A1 (en) | 2007-06-28 |
GB0625855D0 (en) | 2007-02-07 |
JP2007214113A (en) | 2007-08-23 |
GB0625854D0 (en) | 2007-02-07 |
DE102006062147A1 (en) | 2007-11-15 |
GB0625852D0 (en) | 2007-02-07 |
JP4810418B2 (en) | 2011-11-09 |
TWI343060B (en) | 2011-06-01 |
JP2007191711A (en) | 2007-08-02 |
TWI338024B (en) | 2011-03-01 |
GB2433742B (en) | 2010-09-08 |
TW200724552A (en) | 2007-07-01 |
US20070179235A1 (en) | 2007-08-02 |
DE102006062148A1 (en) | 2007-08-16 |
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