WO2019194755A1 - Composé extrudable pour panneau composite à base d'aluminium ayant une résistivité au feu de classe a2 et procédé de fabrication d'un panneau composite à base d'aluminium l'utilisant - Google Patents

Composé extrudable pour panneau composite à base d'aluminium ayant une résistivité au feu de classe a2 et procédé de fabrication d'un panneau composite à base d'aluminium l'utilisant Download PDF

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Publication number
WO2019194755A1
WO2019194755A1 PCT/TR2018/050146 TR2018050146W WO2019194755A1 WO 2019194755 A1 WO2019194755 A1 WO 2019194755A1 TR 2018050146 W TR2018050146 W TR 2018050146W WO 2019194755 A1 WO2019194755 A1 WO 2019194755A1
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WO
WIPO (PCT)
Prior art keywords
composite panel
extrudable
pdms
compounds
flame retardant
Prior art date
Application number
PCT/TR2018/050146
Other languages
English (en)
Inventor
Hüseyin Öztürk
Original Assignee
Hdo Plastik Sanayi Ve Ticaret Limited Sirketi
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Hdo Plastik Sanayi Ve Ticaret Limited Sirketi filed Critical Hdo Plastik Sanayi Ve Ticaret Limited Sirketi
Priority to PCT/TR2018/050146 priority Critical patent/WO2019194755A1/fr
Publication of WO2019194755A1 publication Critical patent/WO2019194755A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K21/00—Fireproofing materials
    • C09K21/02—Inorganic materials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/08—Copolymers of ethene
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K21/00—Fireproofing materials
    • C09K21/02—Inorganic materials
    • C09K21/04—Inorganic materials containing phosphorus
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2201/00—Properties
    • C08L2201/02—Flame or fire retardant/resistant

Definitions

  • the present invention relates to extrudable thermoplastic resin compound for building panel at A2 class fire resistivity.
  • the building panel such as a flooring panel or wall panel and the use thereof to form floors, walls, cladding, etc., by assembling a plurality of the panels and thermoplastic core materials produced by the extrudable thermoplastic resin compound at A2 class fire resistivity according to EN 13501 -1 .
  • the European standard EN 13501-1 Fire classification of construction products and building elements-Part 1 : Classification using test data from reaction to fire tests provides a number of performance criteria to measure the fire characteristics of building products. These cover spread of flame and contribution to fire as well the generation of smoke and the production of burning droplets esc. as seen detailed in Table-1
  • total heat release rate of A2 class fire resistive aluminium composite panel (ACP) material should be equal or less than 3 MJ/kg.
  • A2 class ACP core material Main reason behind the unprocessability of A2 class ACP core material is high filling ratio of polymeric materials given rise to deterioration of structure integrity of the compounds.
  • Single screw extrusion line coupled with a flat die is the most common method is used by manufacturer of B1 or B2 class ACP.
  • A2 class core material in coil form having cloths to be able to obtain structure integrity. It is clear that using core materials in coil form have resulted in requirements of investing for a new machine or modifying existing production line. Investment cost, loss at productivity and less flexibility of production, difficulties of adhering coil onto aluminum sheets, storage cost of A2 coil and availability of A2 coil at required time are the disadvantages of the manufacturing technique of ACP at A2 class with using coil.
  • extrudable A2 class fire resistive compounds in granule or pellet form has crucial importance for ACP manufacturer.
  • Extrudable A2 compounds can be used directly in extrusion line coupled with flat die that already used for B1 and/or B2 class fire resistive ACP manufacturing.
  • using A2 extrudable compound in manufacturing line allows increasing productivity, production speed, and flexibility.
  • manufacturers of ACP can directly be use existing facilities without any additional investment nor modification in case of using A2 extrudable compounds.
  • Coil usage at ACP manufacturing cause batch-wise manufacturing, while A2 extrudable compounds results in continuous manufacturing methods which ensures uniform product quality with low cost.
  • the patent numbered CN201399940 disclose a utility to be able to produce A2 class fire resistive ACP in a continuous manner.
  • the compounds used for core material coupled with fabric to ensure structure integrity, in addition, reprocess ability or extrudablity was not a major concern of this patent.
  • Another patent CN205255632 suggested obtaining a core material with A2 class fire resistivity using 10%acrylic acid and 90% inorganic materials.
  • the method to prepare core material is not mentioned in the patent. Again, process ability and extrudability is not the main subject of the patent.
  • Patent CN102242559 relates to color mirror fireproof aluminum-plastic composite panel at A2 fire resistivity. However, manufacturing of A2 class fire resistive core material is out of scope of the subject of the patent.
  • Another patent CN102585337 claimed manufacturing of extrudable core material at A2 class fire resistive for panels according to standard GB20286-2006.
  • the authors of the patent clearly express that core material mentioned in the patent can only meet the requirements of total heat release rate equal or less than 4 MJ/kg, not than 3 MJ/kg. Therefore, it is obvious that core material mentioned in the patent cannot be classified as A2 class fire resistive material according to European standard EN 13501 -1 that require total heat release rate must be 3 MJ/kg.
  • extrudable A2 class fire resistive thermoplastic core material compounds in comply with the European standard EN 13501 -1 are not available and could not be produced by a company.
  • this patent disclose the extrudable thermoplastic compounds used for ACP manufacturing at A2 class fire resistivity according to EN 13501 -1.
  • Fire-resistive rating can be described as the time that the material or construction will withstand fire exposure as determined by a fire test made in conformity with the standard methods of fire tests of building, construction and materials. To be able to reach A2 class fire resistivity, compound formulations have crucial importance to fulfill the requirement of EN 13501 -1 standard.
  • Compounding is a kind of process for preparing polymeric materials with a specific formulations by extruder/compounder in a way that mixing or and blending polymers, additives and inorganic materials in a molten state.
  • A2 class fire resistive ACP core materials compounds can be produced by continuous compounding process via co-rotating or counter rotating twin-screw compounders, single screw compounders, co-kneaders or extruders. Besides that, Batch-wise production method with a banbury or an equipment similar to banbury can also be used for compounding process of A2 class fire resistive ACP core materials compounds.
  • Present invention of this patent comprises of reprocess ability of said A2 class fire resistive ACP core materials compounds by an extrusion method coupled with a flat die or an equipment similar to flat die for ACP manufacturing.
  • linear low density polyethylene LLDPE
  • low density polyethylene LDPE
  • mixture of them or recycled form of those polymers were used as carrier medium of flame-retardant materials.
  • present invention of this patent proposed such thermoplastic resins as polymeric medium.
  • thermoplastic resins are polyoxymethylene (POM), polymeric form of ethylene vinyl acetate (EVA), polyamide 6 (PA 6), polyamide 6.6 (PA 6.6), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polymethyl methacrylate, (PMMA), polybuthyl acrylate (PBA), polystyrene (PS), polyolefin elastomers (POE), polycarbonate (PC), Ethylene-Propylene Rubber (EPR), Styrene- butadiene-styrene (SBS), Styrene-ethylene-butylene-Styrene (SEBS), ethylene-butyl acrylate copolymers (EBA), ethylene-ethyl acrylate copolymers (EEA) or mixtures of said thermoplastic resins in any variations.
  • the invention of this patent comprise using thermoset polymers such as epoxies, unsaturated polyesters, and thermoplastic vulf
  • Present invention comprise of polymer type and mixtures of polymers take place in A2 class fire resistive compound formulation.
  • Polymer type and mixtures of polymers amount can be wt. % of 6 to 20, more preferably wt. % 7 to 18, more preferably wt. % of polymer mixture can be about 8 to 15%.
  • Flame retardant materials are the any substance that by chemical or physical action reduces flammability of fuels or slows their rate of combustion.
  • Magnesium dihydroxide or aluminum trihydroxide are the well-known flame retardant materials for ACP manufacturing. Even though halogen containing flame retardant flame retardant materials are available, their usage are limited due to global regulation. Therefore, halogen-containing flame retardant materials is out of scope of present invention.
  • Present invention comprise synergist such as zinc borate Zinc hydroxystannate, zinc stannate, and nanoclays are also be used to enhance fire resistivity of said A2 class fire resistive extrudable core material compounds.
  • Present invention comprise of MDH usage as flame retardant material in about 80 to 94 wt. %.
  • Present invention comprise particle size of MDH varying from 0.5 to 3000 micrometer, more preferably from 1 to 2000 micrometer, more preferably 1 -1000 micrometer, more preferably from 1 to 100 micrometer.
  • Present invention comprise of ATH usage as flame retardant material in about 80 about 94 wt. %.
  • Present invention comprise particle size of ATH varying from 0.5 to 3000 micrometer, more preferably from 1 to 2000 micrometer, more preferably 1 -1000 micrometer, more preferably from 1 to 100 micrometer.
  • Present invention comprise of magnesium carbonate usage as flame retardant material in about 80 to 94 wt. %.
  • Present invention comprise particle size of magnesium carbonate varying from 0.5 to 3000 micrometer, more preferably from 1 to 2000 micrometer, more preferably 1 -1000 micrometer, more preferably from 1 to 100 micrometer.
  • Present invention comprise of calcium carbonate usage as flame retardant material in about 80 to 94 wt. %.
  • Present invention comprise particle size of calcium carbonate varying from 0.5 to 3000 micrometer, more preferably from 1 to 2000 micrometer, more preferably 1 -1000 micrometer, more preferably from 1 to 100 micrometer.
  • Present invention comprise of APP usage as flame retardant material in about 80-94 wt. %.
  • Present invention comprise particle size of APP varying from 0.5 to 50 micrometer.
  • Present invention comprise of usage of mixtures of ATH, MDH, Magnesium Carbonate, Calcium Carbonate and APP in any combinations of said materials as flame retardant material in about 80 to 94 wt. %.
  • Present invention comprise particle size of flame-retardants varying from 0.5 to 3000 micrometer.
  • Present invention comprise usage of Zinc borate Zinc hydroxystannate and zinc stannate, and nanoclays.
  • the said synergists can be used in varying amount from 0,1 to 10 wt. %, more preferably from 1 to 7 w %, more preferably from 2 to 5 wt. %.
  • Present invention also comprise coupling agent usage in compounding formulation.
  • Maleic anhydride grafted LLDPE MAH-g-LLDPE
  • Maleic anhydride grafted PP MAH-g-PP
  • Maleic anhydride grafted POE MAH-g-POE
  • silane-coupling agents such as vinyl trimethoxysilane (VTMS), vinyl triethoxysilane (VTES), and amino propyl triethoxysilane (APTES) can be used to enhance compatibility of polymeric materials and inorganic materials.
  • Present invention comprise using MAH-g-POE in A2 class fire resistive compound formulation.
  • MAH-g-POE can be used at varying amount from 0,1 to 6 wt. %, more preferably from 0,5 to 4 wt. %, more preferably from 2 to 4 wt. %.
  • Present invention comprise usage of lubricants as well.
  • lubricants Besides magnesium stearate, calcium stearate, polyethylene (PE) wax, EVA wax, polydimethyl siloxane (PDMS), PDMS-LLDPE, PDMS-PMMA, PDMS-PBA, PDMS-EBA, PDMS-EEA copolymers can be use as lubricant successfully.
  • PDMS can be used as lubricant in varying amount from 0,1 to 10 wt. %, more preferably from 0,5 to 8 wt. %, more preferably from 0,5 to 5 wt. %.
  • the formulations above are processed at banbury, co-kneader, single screw, co-rotating or counter-rotating twin-screw compounder line, then converted into pellet or granule form allowing to re-extrudable into desired shape by using a conventional extrusion coupled with flat die for manufacturing ACP.
  • the compounds above can comply with specifications of A2 class fire resistivity of EN 13501 -1.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

La présente invention concerne la formulation et le procédé de production de composés de résine thermoplastique pour la fabrication d'un panneau composite aluminium-plastique ayant une résistivité au feu de classe A2 selon la norme EN 13501-1. Lesdits composés de résine thermoplastique peuvent être produits sous forme de pastilles, de granulés à l'aide d'un mélangeur monovis ou bivis continu, d'un mélangeur Banbury et d'un co-malaxeur. Lesdits composés peuvent être retransformés selon la forme recherchée par une extrudeuse bivis ou une extrudeuse monovis couplée à une filière plate sur une ligne de fabrication de panneaux composites à base d'aluminium classique. Les composés selon la présente invention apportent efficacité de coût, et flexibilité aux fabricants de panneaux composites à base d'aluminium. Ainsi, les composés ci-décrits permettent de fabriquer un panneau composite à base d'aluminium sans recourir à des matériaux de base bobinés nécessitant un investissement en machines.
PCT/TR2018/050146 2018-04-05 2018-04-05 Composé extrudable pour panneau composite à base d'aluminium ayant une résistivité au feu de classe a2 et procédé de fabrication d'un panneau composite à base d'aluminium l'utilisant WO2019194755A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/TR2018/050146 WO2019194755A1 (fr) 2018-04-05 2018-04-05 Composé extrudable pour panneau composite à base d'aluminium ayant une résistivité au feu de classe a2 et procédé de fabrication d'un panneau composite à base d'aluminium l'utilisant

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/TR2018/050146 WO2019194755A1 (fr) 2018-04-05 2018-04-05 Composé extrudable pour panneau composite à base d'aluminium ayant une résistivité au feu de classe a2 et procédé de fabrication d'un panneau composite à base d'aluminium l'utilisant

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WO2019194755A1 true WO2019194755A1 (fr) 2019-10-10

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005071006A1 (fr) * 2004-01-22 2005-08-04 Dow Corning Corporation Composition presentant une adhesion amelioree a materiau durcissable par addition et article composite incorporant une telle composition
KR100680822B1 (ko) * 2005-09-21 2007-02-08 진영테크주식회사 비할로겐계 난연성 폴리올레핀 수지조성물
WO2010008182A2 (fr) * 2008-07-14 2010-01-21 (주)네오엑스테크 Composition pour âme de panneau composite en aluminium incombustible
WO2010062113A2 (fr) * 2008-11-25 2010-06-03 Jinyoungtech Co., Ltd Composition de résine de polyoléfine ignifuge thermo-expansible et panneau composite ignifuge l'utilisant
US20140170238A1 (en) * 2012-12-18 2014-06-19 Basf Se Antimicrobial effects in polymers

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005071006A1 (fr) * 2004-01-22 2005-08-04 Dow Corning Corporation Composition presentant une adhesion amelioree a materiau durcissable par addition et article composite incorporant une telle composition
KR100680822B1 (ko) * 2005-09-21 2007-02-08 진영테크주식회사 비할로겐계 난연성 폴리올레핀 수지조성물
WO2010008182A2 (fr) * 2008-07-14 2010-01-21 (주)네오엑스테크 Composition pour âme de panneau composite en aluminium incombustible
WO2010062113A2 (fr) * 2008-11-25 2010-06-03 Jinyoungtech Co., Ltd Composition de résine de polyoléfine ignifuge thermo-expansible et panneau composite ignifuge l'utilisant
US20140170238A1 (en) * 2012-12-18 2014-06-19 Basf Se Antimicrobial effects in polymers

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