Retardant fillers endothermic

It is self evident that mineral fillers need to be stable at the temperatures (up to 350 °C) experienced in processing thermoplastics. Most fillers are stable to much higher temperatures and so this is not usually an issue. However, it is a very important topic for flame retardant fillers which function by decomposing endothermically with the release of inert gasses. To be effective, this decomposition must occur near to the temperature at which the polymer begins to decompose and release flammable volatiles. This is usually not too much above the processing temperature in the case of thermoplastics and hence the exact temperature at which decomposition commences is of great importance. The size and position of the endotherm and the rate at which the inert gas is released are also of importance to the flame retardant effect itself [23]. 

Aluminium hydroxide has a Moh hardness of about 3 and a specific gravity of 2.4. It decomposes endothermically with the release of water at about 200 °C and this makes it a very useful flame retardant filler, this being the principal reason for its use in polymers. The decomposition temperature is in fact too low for many thermoplastics applications, but it is widely used in low smoke P VC applications and finds some use in polyolefins. For these applications low aspect ratio particles with a size of about 1 micron and a specific surface area of 4-10 m g are preferred. The decomposition pathway can be diverted through the mono-hydrate by the application of pressure, and this may reduce the flame retardant effect [97]. This effect can be observed with the larger sized particles. Although it is chemically the hydroxide, it has for many years been known as alumina trihydrate and by the acronym ATH. 

Since the decomposition reaction occurs at a specific temperature, the performance of these fillers depends on the properties of the polymers in which they are used. For example, Mg(0H)2 performs better in polyethylene than AlfOI I) because it remains stable during compounding and decomposes at a temperature closer to the decomposition of PE (300-400 C). In unsaturated polyesters, Al(0H)3 starts to release water at 200°C. The major endothermic peak occurs at 300°C with a heat of decomposition of 300 kJ/mol. About 90% of the water is released between 200 and 400 C. A considerable amount of heat is absorbed before the polymer is affected. The water also dilutes combustible gases and hinders the access of oxygen to the polymer surface. Figure 12.8 shows the difference between talc and a fire retardant filler in PP." Talc causes an increase in the combustion rate as its concentration increases, whereas Mg(OH)2, used at a sufficient concentration (above 20%), decreases the rate of combustion. 

Fire Retardant Fillers that Rely on Endothermic Decomposition... 

Aluminium hydroxide is essentially non-toxic, but does require high addition levels to be effective. As a result, the physical properties of the compound usually suffer. Its fire retardancy action results from the endothermic reaction which releases water under fire conditions and produces a protective char . The endothermic reaction draws heat from the rubber/filler mass and thus reduces the thermal decomposition rate. The water release dilutes the available fuel supply, cooling the rubber surface and mass. 

The performance of aluminium hydroxide/magnesium hydroxide-filled systems can be enhanced by incorporation of zinc hydroxystannate in halogen-free rubbers giving reduced smoke and toxic gas emission, coupled with higher flame retardancy. This action will be complimentary to the water release and endothermic effects of aluminium hydroxide/magnesium hydroxide filler systems. 

One of the emerging technologies that is showing great promise is the use of hydrated mineral fillers such as aluminium and magnesium hydroxides, as such materials can provide high levels of flame retardancy without the formation of smoke or corrosive and potentially toxic fumes. The use of fillers as flame retardants has recently been reviewed by Rothon [23]. Essentially the key features are an endothermic decomposition to reduce the temperature, the release of an inert gas to dilute the combustion gases and the formation of an oxide layer to insulate the polymer and to trap and oxidise soot precursors. 

Flame-retardants are used as additives in the preparation of fire retardant paints. They are decomposed by heat to produce nonflammable components, which are able to blanket the flames. Both inorganic and organic types of flame-retardants are available in the market. The most widely used inorganic flame-retardants are aluminum trihydroxide, magnesium hydroxide, boric acid, and their derivatives. These substances have a flame-retardant action mainly because of their endothermic decomposition reaction and their dilution effect. The disadvantage of these solids is that they are effective in very high filler loads (normally above 60 percent). 

Miscellaneous. These approaches include dilution of the polymer with nonflammable materials (for example, inorganic fillers), incorporation of materials that decompose to nonflammable gases such as carbon dioxide, and formulation of products that decompose endothermically. A typical example of such a flame retardant is aluminum oxide trihydrate (AI2O3.3H2O). This type of material acts as a thermal sink to increase the neat capacity of the combusting system, lower the polymer surface temperature via endothermic events, and dilute the oxygen supply to the flame, thereby reducing the fuel concentration needed to sustain the flame. 

Hydrated fillers such as ATH achieve their flame-retarding characteristics by endothermically decomposing with the release of water close to the temperature at which the polymers themselves decompose (see Chapter 17). They do not have the smoke and corrosive gas problems associated with other types of flame retardants. In order to produce an acceptable HFFR compound at very high ATH loadings of 60-65 wt%, the ATH particle size and shape have to be carefully controlled. Experience suggests that large and thick ATH particles with a low surface area are... 

Aluminium trihydrate (ATH) is also known as hydrated alumina. It is the most widely used FR additive in volume terms, representing 43% of all flame-retardant chemicals in volume (but only about 29% in value). As well as flame retarding and smoke suppressing, it is an economical filler/extender. In a fire, it undergoes an endothermic dehydration with a twofold action, simultaneously absorbing... 

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