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Fire resistace acoustic foam

A foam, polymer technology, applied in the field of fire-resistant acoustic foam, which can solve undescribed problems

Inactive Publication Date: 2004-07-14
DOW GLOBAL TECH LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

However, the patent does not describe macrocellular foams or flame retardant macrocellular foams for acoustic applications or their preparation

Method used

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  • Fire resistace acoustic foam
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Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0159] The following examples illustrate the effect of additive (antimony trioxide, builder) particle size on the obtained foam cell size. The examples also detail the flame retardant formulations used to make the PP / PE blend acoustic foams of the present invention and the method of making such foams by extrusion. The foams listed in Table 1 were prepared in standard extrusion equipment. The levels of additives used in the formulation (whether they were added as powders or as concentrates) are reported in phr. Blowing agent levels used in the formulation are reported in parts by weight per hundred parts by weight total feed (polymer and additives) (pph).

[0160] Comparative Formulation 1 in Table 1 was run using a 60% / 40% blend (by weight) of HMS PP1 and LDPE1 with the following additives: 0.5phr Irganox 1010, 0.2phr Ultranox 8 15A, 0.5phr Atmer 129 GMS, 0.4phr 50 BK 70 carbon black, 5phr PE-68 brominated flame retardant and 0.5phr antimony trioxide synergist. The isobutan...

Embodiment 2

[0168] The following examples illustrate the effect of additive (antimony trioxide, builder) particle size on the obtained foam cell size. This example also details the flame retardant formulations used to make the PE acoustic foams of the present invention and the method of making such foams by extrusion. The foams listed in Table 2 were prepared in standard extrusion equipment.

Embodiment 2B

[0172] Example 2B formulation.

[0173] The results obtained using the above examples are summarized in Table 2 below.

[0174] Example *

base resin

flame retardant

Flame Retardant Synergist

average pore size

Control 2a *

LDPE 2

PE-68

0phr

n / a

0phr

>10mm

Comparative example 2 *

LDPE 2

PE-68

11phr

TRUTINT

50

1.3

phr

7.7mm

Control 2b **

LDPE 2

PE-68

0phr

n / a

0phr

>10mm

Example

2A **

LDPE 2

PE-68

11phr

MICROFINE

AO-3

2phr

9.1mm

Example

2B **

LDPE 2

PE-68

6phr

MICROFINE

AO-3

3phr

7.7mm

[0175] * Other ingredients in each first example formulation:

[0176] Irganox-1010: 0.3phr, Atmer 1013 GMS: 1.0phr, Plasblak PE-3037 carbon black: 0.375phr, isobutane as blowing agent: 8.3pph

[0177] ** Other ingredients in each ex...

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PUM

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Abstract

The present invention describes macrocellular foams having, among other features, improved cell size and flame test response properties, obtained by selecting a flame retardant aid with a particle size of less than 1 micron. The inventors have discovered that increasing the amount of flame retardant aid for a given foam cell size, or increasing the foam cell size for a given amount of flame retardant aid, allows foams with exceptionally large, well-formed cells, The foam has excellent flame test response characteristics. The benefits of thermoplastic foam and inorganic flame retardant aids are particularly noteworthy due to the unexpected reduction in the nucleation effect of the aid. Foam is used to improve the acoustic performance of the product, and the product is required to meet certain flame test response characteristics. It can be used in automobiles and other transportation equipment, buildings and construction, household and garden appliances, power tools and appliances, and power supply housings, connectors, and aircraft as sound-absorbing and sound-insulating acoustic systems.

Description

Background technique [0001] Foam and foamed articles often find use in acoustic systems for sound absorption and sound insulation. Such foams, when developed for use in different market segments (appliances, automotive, building and construction, etc.), typically need to meet certain acoustic performance requirements and applicable flame test response characteristics (ASTM E176-99). Various flame retardant components are often added to such foam resin formulations in order to achieve the desired fire resistance rating. Unfortunately, typical flame retardant components and other additives added to polymer resin formulations cause a number of problems during foam manufacture that have an adverse effect on obtaining acoustically active macrocellular foams. Due to their effect on polymer gel viscosity and melt strength, flame retardants generally cause poor cell structure and cell collapse. To reduce the need for high concentrations of flame retardants, flame retardant aids are ...

Claims

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Application Information

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IPC IPC(8): C08J9/04C08J9/00C08K3/22C08L23/10
CPCC08J9/0019C08J9/0023C08J9/00
Inventor S·比尔甘J·卡默勒C·P·朴W·G·斯托比S·苏布拉芒尼安
Owner DOW GLOBAL TECH LLC
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