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US 8,044,130 B2Granted
Surface-coated flame-retardant particle and method of producing the same, and flame-retardant resin composition and method of producing the same
AssigneeFuji Xerox Co., Ltd.
InventorsTsuyoshi Miyamoto, Masayuki Okoshi
Life of this patent
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Abstract
A surface-coated flame-retardant particle comprising a flame-retardant grain and a coated layer provided on a surface of the flame-retardant grain, wherein the coated layer comprises an organic compound or a polysilicone, the flame-retardant grain comprises a metal hydrate and has a volume average particle diameter of 1 to 500 nm, and the metal hydrate comprises Mg and at least one of Ca, Al, Fe, Zn, Ba, Cu, and Ni. Also provided is a flame-retardant resin composition comprising the surface-coated flame-retardant particle.
Claims21
Surface-coated flame-retardant particles comprising a flame-retardant grain and a coated layer provided on a surface of the flame-retardant grain,
- wherein the coated layer comprises an organic compound which has a binding group for combining with the flame-retardant grains at its terminal, or a polysilicone, the flame-retardant grain comprises a complex metal hydrate and has a volume average particle diameter of 1 to 500 nm, and the complex metal hydrate is represented by MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni, x is a real number of 0.1 to 10, and y is an integer of 2 to 32;
- and
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion=log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
6 more elements
A flame-retardant resin composition comprising a matrix resin and surface-coated flame-retardant particles mixed with the matrix resin,
- wherein the surface-coated flame-retardant particles each comprise a flame-retardant grain and a coated layer provided on a surface of the flame-retardant grain, the coated layer comprises an organic compound which has a binding group for combining with the flame-retardant grains at its terminal, or a polysilicone, the flame-retardant grains comprise a complex metal hydrate and have a volume average particle diameter of 1 to 500 nm, and the complex metal hydrate is represented by MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni, x is a real number of 0.1 to 10, and y is an integer of 2 to 32;
- and
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion =log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
6 more elements
A method of producing surface-coated flame-retardant particles, the method comprising:
- forming a dispersion liquid by dispersing flame-retardant grains in an aqueous solution in which a metal salt of an organic compound and a dispersant are dissolved;
- and
- forming a coated layer by depositing the organic compound on the flame-retardant grains by adding an acidic aqueous solution to the dispersion liquid,
- wherein the flame-retardant grains comprise a complex metal hydrate and have a volume average particle diameter of 1 to 500 nm, and the complex metal hydrate is represented by MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni x is a real number of 0.1 to 10, and y is an integer of 2 to 32;
- and
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion =log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
9 more elements
A method of producing surface-coated flame-retardant particles, the method comprising:
- forming a dispersion liquid by dispersing flame-retardant grains in a solution in which an organic compound and a dispersant are dissolved in an organic solvent miscible with water;
- and
- forming a coating layer by depositing the organic compound on a surface of the flame-retardant grains by adding water to the dispersion liquid,
- wherein the flame-retardant grains comprise a complex metal hydrate and have a volume average particle diameter of 1 to 500 nm, and the complex metal hydrate is represented by MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni x is a real number of 0.1 to 10, and y is an integer of 2 to 32;
- and
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion =log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
9 more elements
A method of producing surface-coated flame-retardant particles, the method comprising:
- forming a dispersion liquid by dispersing flame-retardant grains in an aqueous solution in which a dispersant is dissolved;
- and
- adding an aqueous solution of a salt of a polyamino acid to the dispersion liquid so as to form a coating layer through deposition of the polyamino acid on the flame-retardant grains,
- wherein the flame-retardant grains comprise a complex metal hydrate and have a volume average particle diameter of 1 to 500 nm, and the complex metal hydrate is represented by MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni x is a real number of 0.1 to 10, and y is an integer of 2 to 32;
- and
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion =log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
9 more elements
A method of producing surface-coated flame-retardant particles, the method comprising:
- forming metal soap particles having a micelle structure or a vesicle structure by dissolving a surfactant and a metal salt including MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni, x is a real number of 0.1 to 10, and y is an integer of 2 to 32, in water;
- converting the metal soap particles to reverse micelle particles by suspending the metal soap particles in an organic solvent;
- and
- forming a complex metal hydroxide by allowing the metal ion contained in the reverse micelle particles to react with a base;
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion =log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
8 more elements
A method of producing surface-coated flame-retardant particles, the method comprising:
- forming a suspension liquid obtained by suspending a metal salt of an organic compound in an organic solvent;
- and
- forming a complex metal hydroxide by allowing the metal ion contained in the metal salt of the organic compound to react with a base,
- wherein the metal salt of the organic compound includes MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni, x is a real number of 0.1 to 10, and y is an integer of 2 to 32;
- and
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion =log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
9 more elements
A method of producing surface-coated flame-retardant particles, the method comprising:
- forming a first aqueous solution in which a dispersant or chelate compound, and a metal salt of an organic compound are dissolved;
- adding a second aqueous solution of a metal ion to the first aqueous solution;
- and
- forming a complex metal hydroxide by adding a base to the mixed aqueous solution containing the metal ion,
- wherein the metal salt of the organic compound includes MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni, x is a real number of 0.1 to 10, and y is an integer of 2 to 32;
- and
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion =log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
10 more elements
A method of producing surface-coated flame-retardant particles, the method comprising treating flame-retardant grains having a volume average particle diameter of 1 to 500 nm with vapor of a cyclic organosiloxane compound so as to allow the cyclic organosiloxane compound to undergo ring-opening polymerization on the flame-retardant grains and so as to form a coating layer on the flame-retardant grains,
- wherein the flame-retardant grains comprise a complex metal hydrate is represented by MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni x is a real number of 0.1 to 10, and y is an integer of 2 to 32;
- and
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion =log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
6 more elements
A method of producing a flame-retardant resin composition, the method comprising:
- mixing at least a matrix resin and surface-coated flame-retardant particles;
- and
- kneading the mixture by using at least one kneading machine selected from rolls, a kneader, a Banbury mixer, an intermixer, a uniaxial extruder, and a biaxial extruder,
- wherein the surface-coated flame-retardant particles each comprise a flame-retardant grain and a coated layer provided on the flame-retardant grain, the coated layer comprises an organic compound or a polysilicone, the flame-retardant grains comprise a complex metal hydrate and have a volume average particle diameter of 1 to 500 nm, and the complex metal hydrate is represented by MgMx-(OH)y, wherein M represents one or more metals selected from the group consisting of Ca, Al, Fe, Zn, Ba, Cu, and Ni, x is a real number of 0.1 to 10, and y is an integer of 2 to 32;
- and
- wherein the surface-coated flame-retardant particles have a degree of dispersion from 0.1 to 3.0, the degree of dispersion being defined by the following Formula (1):
- Degree of dispersion =log(D90/D10)
- where:
- in a plot of a mass weighted cumulative distribution of the particles against particle weight from the smaller particle diameter side,
- the particle diameter at which the cumulative distribution reaches the 90% point is designated as D90;
- and
- the particle diameter at which the cumulative distribution reaches the 10% point is designated as D10.
9 more elements
Dependencies are inferred from the claim text.