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Sulfonated polyolefin-based flame retardant material

Inactive Publication Date: 2014-08-14
UT BATTELLE LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This patent describes a new type of flame retardant that can be made from polyolefin-based fibers. These fibers can be fabrics made from weaving the filaments into a flame retardant fabric. The flame retardant properties of the fabric are not compromised when the fibers are treated to make them non-toxic. The treatment involves adding a material that can break down toxic sulfur dioxide fumes that are formed when the fabric is exposed to high temperatures. Overall, the patent describes a way to make a cost-effective, effective flame retardant that can be used in a variety of materials.

Problems solved by technology

Nevertheless, numerous drawbacks and concerns exist with their use.
For example, many flame retardant substances are either too costly, toxic, or difficult to incorporate into a particular material of interest.

Method used

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  • Sulfonated polyolefin-based flame retardant material
  • Sulfonated polyolefin-based flame retardant material
  • Sulfonated polyolefin-based flame retardant material

Examples

Experimental program
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Effect test

example 1

Preparation of Sulfonated Polyolefin (LLDPE) Fiber

[0078]An as-spun tow of neat LLDPE of 1560 filaments (18 micrometer filament diameter) was continuously processed through a two-part reactor containing (1) concentrated sulfuric acid, and (2) oleum with 20% SO3. The speed of the fiber was adjusted to attain proper residence time. A tensile stress of 5 MPa was applied to the fiber during semi-continuous processing. For the concentrated sulfuric acid bath, the temperature was maintained at 115° C. A temperature below 100° C. in the concentrated sulfuric acid bath did not result in an infusible fiber even after 12 hours of treatment. For the oleum bath (which is a concentrated sulfuric acid bath containing dissolved SO3 gas), the temperature was maintained at 90° C. A residence time of 4 hours and 40 minutes was used for the concentrated sulfuric acid and oleum baths, respectively, which resulted in infusible fibers that were found to be hygroscopic under ambient conditions.

[0079]The ol...

example 2

Preparation of Sulfonated Polyolefin (LLDPE) Fiber Using E-beam Irradiation

[0083]The LLDPE fiber tow discussed in Example 1 was e-beam irradiated at 10-1000 kGy to reduce the melting temperature, which in turn accelerated the sulfonation kinetics during subsequent sulfonation reaction. As shown in FIG. 4, increasing radiation dosage results in a reduction in melting temperature of polyethylene fibers with overall heat of fusion, i.e., crystallinity, of the fibers remaining unchanged, even when they were irradiated at 1000 kGy dosage. However, when polyethylene fiber was irradiated in the presence of a SO2 gas and at 500 kGy dose, a significant reduction in crystallinity was observed, as also shown in FIG. 4. This indicates crosslinking of the polymer by the SO2 gas and e-beam. The highly irradiated fibers were dissolved in the sulfonation bath due to vigorous reaction. However, unlike the neat PE fiber sample described in Example 1, the 10 kGy irradiated fiber, when treated with con...

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Abstract

Disclosed herein is a flame retardant composition comprising sulfonated polyolefin and a SO2-scavenging material and / or a flame retardant material that is not a sulfonated polyolefin. Also disclosed is a flame-resistant composite comprising a host material in which is incorporated sulfonated polyolefin as a flame retardant composition. Further disclosed are methods for producing the flame retardant composition and flame-resistant composites.

Description

[0001]The present application claims benefit of U.S. Provisional Application No. 61 / 762,489, filed on Feb. 8, 2013, all of the contents of which are incorporated herein by reference.[0002]This invention was made with government support under Prime Contract No. DE-AC05-000R22725 awarded by the U.S. Department of Energy. The government has certain rights in the invention.FIELD OF THE INVENTION[0003]The present invention relates, generally, to flame retardant materials, and more particularly, to sulfonated forms of such compositions.BACKGROUND OF THE INVENTION[0004]Flame retardant materials are produced in large quantities and incorporated into numerous everyday articles in order to meet fire safety codes and regulations. Nevertheless, numerous drawbacks and concerns exist with their use. For example, many flame retardant substances are either too costly, toxic, or difficult to incorporate into a particular material of interest. Thus, there is a continuing effort to find flame retardan...

Claims

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Application Information

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IPC IPC(8): D06M11/55D03D1/00
CPCD03D1/0035D06M11/55D06M10/008D06M11/36D06M11/44D01F11/06D06M2101/20C08K3/22C08K3/346C08K2201/013D06M10/06D06M11/76D06M2200/30C08L23/32
Inventor NASKAR, AMIT K.PAULAUSKAS, FELIX L.WARREN, CHARLES DAVIDJANKE, CHRISTOPHER J.
Owner UT BATTELLE LLC
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