Flame-retardant synthetic resin articles containing flame-retardant superabsorbent polymer (SAP) particles
View Patent ↗Flame-retardant synthetic resin articles and methods of making the same are provided whereby flame-retardant SAP particles are incorporated into synthetic resins, especially curable thermosettable resins. The SAP particles are most preferably hydrated with an aqueous flame-retardant solution. In this regard, the flame-retardant solution may consist essentially of water alone or a water solution containing one or more water soluble inorganic flame retardants. When SAP particles are hydrated with an aqueous inorganic flame retardant solution, the SAP particles may thereafter be dried to remove substantially the water component. In such a manner, the inorganic flame retardant will remain as a dried residue physically entrained within the SAP particles. As such, the SAP particles serve as a physical matrix in which the inorganic flame retardant is homogenously dispersed. The SAP particles may then be blended with a synthetic resin as is or alternatively may be ground into more finely divided particles which contain the dried residue of the aqueous inorganic flame retardant solution and then blended with a suitable synthetic resin.
1. A flame-retardant article comprising a synthetic resin and flame-retardant superabsorbent polymer (SAP) particles, wherein the flame-retardant superabsorbent polymer particles comprise superabsorbent polymer particles containing a dried residue, in an amount between about 25 wt. % to about 500 wt. % based on the total wt. of the flame retardant superabsorbent polymer particles, of an aqueous inorganic flame retardant solution.
2. The flame-retardant article as in claim 1 , wherein the inorganic flame retardant includes at least one phosphorus-containing flame retardant.
3. The flame-retardant article as in claim 2 , wherein the inorganic flame retardant is at least one selected from the group consisting of phosphoric acid and sodium salt derivatives thereof, phosphorous acid and sodium salt derivatives thereof, ammonium orthophosphate, ammonium hypophosphate, ammonium hydrogen phosphate, ammonium dihydrogen phosphate, ammonium hypophosphite, and ammonium dihydrogen orthophosphite.
4. The flame-retardant article as in claim 1 , wherein the inorganic flame retardant is at least one selected from the group consisting of boric acid, sodium tetraborate and hydrates thereof, sodium metaborate and hydrates thereof, and zinc borate.
5. The flame-retardant article of claim 1 , wherein the synthetic resin is at least one selected from the group consisting of acrylic resins, urethane resins, polyester resins, vinyl esters, epoxy resins, phenol/formaldehyde resins, urea/formaldehyde resins, melamine/formaldehyde resins, alkyd resins and acrylate resins.
6. The flame-retardant article of claim 1 , wherein the synthetic resin comprises a crosslinked acrylic resin derived from substituted acrylates.
7. The flame-retardant article of claim 6 , wherein the substituted acrylates comprise epoxy acrylates, hydroxy acrylates, isocyanato acrylates, urethane acrylates or polyester acrylates.
8. The flame-retardant article of claim 1 , wherein the synthetic resin comprises an acrylate resin crosslinked with at least one of a melamine resin, urea resin, isocyanate resin, isocyanurate resin, carbamate resin or epoxy resin.
9. The flame-retardant article of claim 1 , wherein the synthetic resin is a cured thermoset resin.
10. A method of making a flame-retardant synthetic resin article comprising incorporating into a synthetic resin, flame-retardant superabsorbent polymer (SAP) particles, wherein the flame-retardant superabsorbent polymer particles comprise superabsorbent polymer particles containing a dried residue, in an amount between about 25 wt. % to about 500 wt. % based on the total wt. of the flame retardant superabsorbent polymer particles, of an aqueous inorganic flame retardant solution.
11. The method as in claim 10 , wherein the inorganic flame retardant includes at least one phosphorus-containing flame retardant.
12. The method as in claim 11 , wherein the inorganic flame retardant is at least one selected from the group consisting of phosphoric acid and sodium salt derivatives thereof, phosphorous acid and sodium salt derivatives thereof, ammonium orthophosphate, ammonium hypophosphate, ammonium hydrogen phosphate, ammonium dihydrogen phosphate, ammonium hypophosphite, and ammonium dihydrogen orthophosphite.
13. The method as in claim 10 , wherein the inorganic flame retardant is at least one selected from the group consisting of boric acid, sodium tetraborate and hydrates thereof, sodium metaborate and hydrates thereof, and zinc borate.
14. The method of claim 10 , wherein the synthetic resin is at least one selected from the group consisting of acrylic resins, urethane resins, polyester resins, vinyl esters, epoxy resins, phenol/formaldehyde resins, urea/formaldehyde resins, melamine/formaldehyde resins, alkyd resins and acrylate resins.
15. The method of claim 10 , wherein the synthetic resin comprises a crosslinked acrylic resin derived from substituted acrylates.
16. The method of claim 15 , wherein the substituted acrylates comprise epoxy acrylates, hydroxy acrylates, isocyanato acrylates, urethane acrylates or polyester acrylates.
17. The method of claim 10 , wherein the synthetic resin comprises an acrylate resin crosslinked with at least one of a melamine resin, urea resin, isocyanate resin, isocyanurate resin, carbamate resin or epoxy resin.
18. The method of claim 10 , wherein the synthetic resin is a cured thermoset resin.
19. A flame-retardant article comprising cured thermoset resin and flame-retardant superabsorbent polymer (SAP) particles, wherein the flame-retardant superabsorbent polymer particles comprise superabsorbent polymer particles containing a dried residue, in an amount between about 25 wt. % to about 500 wt. % based on the total wt. of the flame retardant superabsorbent polymer particles, of an aqueous inorganic flame retardant solution.
20. The flame-retardant article as in claim 19 , wherein the inorganic flame retardant includes at least one phosphorus-containing flame retardant.
21. The flame-retardant article as in claim 20 , wherein the inorganic flame retardant is at least one selected from the group consisting of phosphoric acid and sodium salt derivatives thereof, phosphorous acid and sodium salt derivatives thereof, ammonium orthophosphate, ammonium hypophosphate, ammonium hydrogen phosphate, ammonium dihydrogen phosphate, ammonium hypophosphite, and ammonium dihydrogen orthophosphite.
22. The flame-retardant article as in claim 19 , wherein the inorganic flame retardant is at least one selected from the group consisting of boric acid, sodium tetraborate and hydrates thereof, sodium metaborate and hydrates thereof, and zinc borate.
23. A method of making a cured flame-thermoset resin article comprising the steps of:
(a) blending an uncured synthetic resin and flame-retardant superabsorbent polymer (SAP) particles, wherein the flame-retardant superabsorbent polymer particles comprise superabsorbent polymer particles containing a dried residue, in an amount between about 25 wt. % to about 500 wt. % based on the total wt. of the flame retardant superabsorbent polymer particles, of an aqueous inorganic flame retardant solution,
(b) curing the blend of uncured synthetic resin and flame-retardant superabsorbent polymer particles to form the cured flame-retardant thermoset resin article.
24. The method of claim 23 , wherein prior to step (a) there is practiced the step of hydrating SAP particles with an aqueous inorganic flame-retardant solution.
25. The method of claim 24 , which further comprises drying the hydrated SAP particles to remove water and leave a dried residue of the inorganic flame-retardant solution physically within the SAP particles.
26. The method as in claim 23 , wherein the inorganic flame retardant includes at least one phosphorus-containing flame retardant.
27. The method as in claim 26 , wherein the inorganic flame retardant is at least one selected from the group consisting of phosphoric acid and sodium salt derivatives thereof, phosphorous acid and sodium salt derivatives thereof, ammonium orthophosphate, ammonium hypophosphate, ammonium hydrogen phosphate, ammonium dihydrogen phosphate, ammonium hypophosphite, and ammonium dihydrogen orthophosphite.
28. The method as in claim 23 , wherein the inorganic flame retardant is at least one selected from the group consisting of boric acid, sodium tetraborate and hydrates thereof, sodium metaborate and hydrates thereof, and zinc borate.