Flame retardant composites

Abstract

A flame retardant polymer composite is disclosed. The composite includes a polymer base material and a flame retardant filler provided in the polymer base material, the flame retardant filler containing seeded boehmite particulate material having an aspect ratio of not less than 3:1

1 . A flame retardant polymer composite, comprising: 
 a polymer base material; and    a flame retardant filler provided in the polymer base material, the flame retardant filler comprising seeded boehmite particulate material having an aspect ratio of not less than 3:1.    
     
     
         2 . The composite of  claim 1 , wherein the composite has a flame retardancy of V-0 or V-1 according to UL94  
     
     
         3 . The composite of  claim 2 , wherein the composite has a flame retardancy of V-0.  
     
     
         4 . The composite of  claim 2 , wherein the composite has said flame retardancy in cured form.  
     
     
         5 . The composite of  claim 4 , wherein the composite is a polymer component.  
     
     
         6 . The composite of  claim 4 , wherein the composite is in the form of a surface coating solution, the composite having said flame retardancy in coated form.  
     
     
         7 . The composite of  claim 1 , wherein the polymer base material has a flame retardancy of V-2 or higher, the filler functioning to improve the flame retardancy to composite to V-1 or V-0 according to UL 94.  
     
     
         8 . The composite of  claim 1 , wherein the polymer base material is selected from the group consisting of polyolefins, polyesters, fluoropolymers, polyamides, polyimides, polycarbonates, polymers containing styrene, epoxy resins, polyurethane, polyphenyl, silicone, and combinations thereof.  
     
     
         9 . The composite of  claim 8 , wherein the polymer base material is a non-chlorinated polymer and is a non-fluorinated polymer, and is selected from the group consisting of polyolefins, polyesters, polyamides, polyimides, polycarbonates, polymers containing styrene, epoxy resins, polyurethane, polyphenyl, and combinations thereof.  
     
     
         10 . (canceled)  
     
     
         11 . (canceled)  
     
     
         12 . (canceled)  
     
     
         13 . (canceled)  
     
     
         14 . (canceled)  
     
     
         15 . The composite of  claim 1 , wherein the composite comprises about 0.5 to 50.0 wt % flame retardant filler.  
     
     
         16 . The composite of  claim 15 , wherein the composite comprises about 2.0 to 30.0 wt % flame retardant filler.  
     
     
         17 . The composite of  claim 16 , wherein the composite comprises about 2.0 to 15.0 wt % flame retardant filler.  
     
     
         18 . The composite of  claim 1 , wherein the seeded boehmite particulate material has an aspect ratio of not less than 4:1.  
     
     
         19 . The composite of  claim 1 , wherein the seeded boehmite particulate material has an aspect ratio of not less than 6:1.  
     
     
         20 . (canceled)  
     
     
         21 . The composite of  claim 1 , wherein the seeded boehmite particulate material predominantly comprises platelet-shaped particles, having a secondary aspect ratio of not less than 3:1.  
     
     
         22 . (canceled)  
     
     
         23 . (canceled)  
     
     
         24 . The composite of  claim 1 , wherein the seeded boehmite particulate material predominantly comprises needle-shaped particles.  
     
     
         25 . The composite of  claim 24 , wherein the needle-shaped particles have a secondary aspect ratio of not greater than 3:1.  
     
     
         26 . (canceled)  
     
     
         27 . The composite of  claim 1 , wherein the average particle size of the seeded boehmite particulate material is not greater than 1000 nm.  
     
     
         28 . The composite of  claim 27 , wherein the average particle size is between about 100 and 1000 nm.  
     
     
         29 . (canceled)  
     
     
         30 . (canceled)  
     
     
         31 . The composite of  claim 28 , wherein the average particle size is not greater than 500 nm.  
     
     
         32 . The composite of  claim 31 , wherein the average particle size is not greater than 400 nm.  
     
     
         33 . (canceled)  
     
     
         34 . The composite of  claim 1 , wherein the boehmite particulate material has a specific surface area of not less than about 10 m 2 /g.  
     
     
         35 . The composite of  claim 34 , wherein the specific surface area is not less than about 50 m 2 /g.  
     
     
         36 . (canceled)  
     
     
         37 . (canceled)  
     
     
         38 . A method of forming a flame retardant polymer composite, comprising: 
 providing a polymer base material; and    combining a flame retardant filler with the polymer base material to form the flame retardant polymer composite, the flame retardant filler comprising seeded boehmite particulate material having an aspect ratio of not less than 3:1.    
     
     
         39 . The method of  claim 38 , further including shape forming following combining, the flame retardant composite being a polymer component.  
     
     
         40 . The method of  claim 38 , wherein the flame retardant composite is a surface coating solution.  
     
     
         41 . The method of  claim 38 , wherein the composite has a flame retardancy of V-0 or V-1 according to UL94.  
     
     
         42 . The method of  claim 41 , wherein the composite has a flame retardancy of V-0.  
     
     
         43 . The method of  claim 38 , wherein the polymer base material has a flame retardancy of V-2 or higher, the filler functioning to improve the flame retardancy to composite to V-1 or V-0 according to UL 94.