Method of flame blocking and articles made therefrom

• US 20070014978A1
• Filed: 07/18/2005
• Published: 01/18/2007
• Est. Priority Date: 07/18/2005
• Status: Abandoned Application

• Current Assignee: ExxonMobil Chemical Patents Inc. (Exxon Mobil Corporation)
• Original Assignee: ExxonMobil Chemical Patents Inc. (Exxon Mobil Corporation)
• Inventors: Poloso, Anthony
• Application Number:
  US11/183,680
• Publication Number:
  US 20070014978A1
• Time in Patent Office: Days
• US Class Current: 428/212
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 37/153 at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/31913 Monoolefin polymer

Abstract

This invention relates to a method of making a pallet assembly comprising: (a) extruding (1) a first layer comprising a flame retardant polyethylene composition comprising a polyethylene having a density ranging from about 0.920 g/cc to about 0.970 g/cc and from about 0.15 wt % to about 40 wt % of a flame retardant material, wherein the wt % is based on the total weight of the first layer; and (2) a second layer comprising a polyolefin polymer composition comprising a polyolefin polymer and less than about 40 wt % of the flame retardant material, wherein the wt % is based on the total weight of the second layer and wherein the wt % of the flame retardant in the second layer is less than the wt % of the flame retardant in the first layer and (b) processing the first layer and the second layer to form the pallet assembly.

Claims

1. A pallet assembly comprising:

(a) a first layer comprising a polyethylene having a density ranging from about 0.920 g/cc to about 0.970 g/cc and from about 0.15 wt % to about 40 wt % of a flame retardant material, wherein the wt % is based on the total weight of the first layer; and

(b) a second layer comprising a polyolefin polymer and less than about 40 wt % of a flame retardant material, wherein the wt % is based on the total weight of the second layer, and

wherein the wt % of the flame retardant in the second layer is less than the wt % of the flame retardant in the first layer.

2. The pallet assembly according to claim 1, wherein the second layer comprises at least about 0.1 wt % of the flame retardant material.

3. The pallet assembly according to claim 1, wherein the first layer and the second layer are co-extruded.

4. The pallet assembly according to claim 1, further comprising a third layer comprising a polyethylene having a density ranging from about 0.920 g/cc to about 0.970 g/cc and up to about 40 wt % of a flame retardant material, wherein (a) the wt % is based on the total weight of the third layer, (b) the second layer is between the first layer and the third layer, and (c) the polyethylene in the third layer may be the same as or different from the polyethylene in the first layer.

5. The pallet assembly according to claim 1, further comprising one or more additional layers between the first layer and the second layer, wherein the additional layers each comprise less than about 1 wt % flame retardant material based on the total weight of each respective layer.

6. The pallet assembly according to claim 4, further comprising one or more additional layers between the second layer and the third layer, wherein the additional layers each comprise less than about 1 wt % flame retardant material based on the total weight of each respective layer.

7. The pallet assembly according to claim 1, wherein the first layer comprises up to about 30 wt % of the flame retardant material.

8. The pallet assembly according to claim 7, wherein the first layer comprises up to about 20 wt % of the flame retardant material.

9. The pallet assembly according to claim 8, wherein the first layer comprises up to about 15 wt % of the flame retardant material.

10. The pallet assembly according to claim 9, wherein the first layer comprises up to about 10 wt % of the flame retardant material.

11. The pallet assembly according to claim 1, wherein the density of the polyethylene ranges from about 0.930 g/cc to about 0.970 g/cc.

12. The pallet assembly according to claim 11, wherein the density of the polyethylene ranges from about 0.940 g/cc to about 0.970 g/cc.

13. The pallet assembly according to claim 12, wherein the density of the polyethylene ranges from about 0.950 g/cc to about 0.960 g/cc.

14. The pallet assembly according to claim 1, wherein the polyolefin polymer comprises a homopolymer or copolymer of at least one of polyethylene, polyethylene blended with an impact modifier, polyethylene regrind or polypropylene.

15. The pallet assembly according to claim 1, wherein the polyolefin polymer comprises the polyethylene, wherein the density ranges from about 0.920 g/cc to about 0.970 g/cc.

16. The pallet assembly according to claim 15, wherein the density of the polyethylene ranges from about 0.930 g/cc to about 0.970 g/cc.

17. The pallet assembly according to claim 16, wherein the density of the polyethylene ranges from about 0.940 g/cc to about 0.970 g/cc.

18. The pallet assembly according to claim 17, wherein the density of the polyethylene ranges from about 0.950 g/cc to about 0.960 g/cc.

19. The pallet assembly according to claim 1, wherein the second layer comprises less than about 30 wt % of the flame retardant material.

20. The pallet assembly according to claim 19, wherein the second layer comprises less than about 20 wt % of the flame retardant material.

21. The pallet assembly according to claim 20, wherein the second layer comprises less than about 10 wt % of the flame retardant material.

22. The pallet assembly according to claim 21, wherein the second layer comprises less than about 1 wt % of the flame retardant material.

23. The pallet assembly according to claim 1, wherein the flame retardant material comprises at least one of a halogenated organic compound, antimony trioxide, alumina trihydrate, or a nitrogenous organic compound.

24. The pallet assembly according to claim 23, wherein the halogenated organic compound comprises at least one of polybrominated biphenyl oxides, decabromodiphenyl oxide, halogenated phosphate esters, tetrabromobisphenol A, or mixtures thereof.

25. The pallet assembly according to claim 23, wherein the nitrogenous organic compound comprises at least one of urea, melamine, or formaldehyde condensates thereof.

26. The pallet assembly according to claim 1, wherein the pallet assembly comprises a pallet, a dunnage tray, a tote bin, a drum, a bottle, or a building panel.

27. A method of making a pallet assembly comprising:

(a) extruding

(1) a first layer comprising a flame retardant polyethylene composition comprising;

a polyethylene having a density ranging from about 0.920 g/cc to about 0.970 g/cc and from about 0.15 wt % to about 40 wt % of a flame retardant material, wherein the wt % is based on the total weight of the first layer; and

(2) a second layer comprising a polyolefin polymer composition comprising;

a polyolefin polymer and less than about 40 wt % of the flame retardant material, wherein the wt % is based on the total weight of the second layer, and

(b) processing the first layer and the second layer to form the pallet assembly.

28. The method according to claim 27, wherein the first layer and the second layer are co-extruded.

29. The method according to claim 27, further comprising:

blending the polyethylene having a density ranging from about 0.920 g/cc to about 0.970 g/cc and up to about 40 wt % of the flame retardant material to form the flame retardant polyethylene composition, wherein the wt % is based on the total weight of the polyethylene composition.

30. The method according to claim 27, further comprising:

blending the polyolefin polymer and less than about 40 wt % of the flame retardant material to form the polyolefin polymer composition, wherein the wt % is based on the total weight of the polyolefin polymer composition.

31. The method according to claim 27, wherein the processing of the first layer and the second layer comprises at least one of single sheet thermoforming, twin sheet thermoforming, co-injection molding, roto-molding or blow molding.

32. The method according to claim 27, further comprising extruding a third layer comprising a polyethylene having a density ranging from about 0.920 g/cc to about 0.970 g/cc and up to about 40 wt % of a flame retardant material, wherein (a) the wt % is based on the total weight of the third layer, (b) the second layer is between the first layer and the third layer, and (c) the polyethylene in the third layer may be the same as or different from the polyethylene in the first layer.

33. The method according to claim 32, further comprising extruding one or more additional layers between the first layer and the second layer, wherein the additional layers each comprise less than about 1 wt % flame retardant material based on the total weight of each respective layer.

34. The method according to claim 33, further comprising extruding one or more additional layers between the second layer and the third layer, wherein the additional layers each comprise less than about 1 wt % flame retardant material based on the total weight of each respective layer.

35. The method according to claim 27, wherein the flame retardant polyethylene composition comprises up to about 30 wt % of the flame retardant material.

36. The method according to claim 35, wherein the flame retardant polyethylene composition comprises up to about 20 wt % of the flame retardant material.

37. The method according to claim 36, wherein the flame retardant polyethylene composition comprises up to about 10 wt % of the flame retardant material.

38. The method according to claim 37, wherein the flame retardant polyethylene composition comprises up to about 1 wt % of the flame retardant material.

39. The method according to claim 27, wherein the density of the polyethylene ranges from about 0.930 g/cc to about 0.970 g/cc.

40. The method according to claim 39, wherein the density of the polyethylene ranges from about 0.940 g/cc to about 0.970 g/cc.

41. The method according to claim 40, wherein the density of the polyethylene ranges from about 0.950 g/cc to about 0.960 g/cc.

42. The method according to claim 27, wherein the polyolefin polymer comprises a homopolymer or copolymer of at least one of polyethylene, polyethylene blended with an impact modifier, polyethylene regrind, or polypropylene.

43. The method according to claim 42, wherein the polyolefin polymer comprises the polyethylene and wherein the density ranges from about 0.920 g/cc to about 0.970 g/cc.

44. The method according to claim 43, wherein the polyolefin polymer comprises the polyethylene and wherein the density ranges from about 0.930 g/cc to about 0.970 g/cc.

45. The method according to claim 44, wherein the polyolefin polymer comprises the polyethylene and wherein the density ranges from about 0.940 g/cc to about 0.970 g/cc.

46. The method according to claim 45, wherein the polyolefin polymer comprises the polyethylene and wherein the density ranges from about 0.950 g/cc to about 0.960 g/cc.

47. The method according to claim 27, wherein the second layer comprises less than about 30 wt % of the flame retardant material.

48. The method according to claim 47, wherein the second layer comprises less than about 20 wt % of the flame retardant material.

49. The method according to claim 48, wherein the second layer comprises less than about 10 wt % of the flame retardant material.

50. The method according to claim 49, wherein the second layer comprises less than about 1 wt % of the flame retardant material.

51. The method according to claim 27, wherein the flame retardant material comprises at least one of a halogenated organic compound, antimony trioxide, alumina trihydrate, or a nitrogenous organic compound.

52. The method according to claim 51, wherein the halogenated organic compound comprises at least one of polybrominated biphenyl oxides, halogenated phosphate esters, tetrabromobisphenol A, or mixtures thereof.

53. The method according to claim 51, wherein the nitrogenous organic compound comprises at least one of urea, melamine, or formaldehyde condensates thereof.

54. The method according to claim 27, wherein the pallet assembly comprises a pallet, a dunnage tray, a tote bin, a drum, a bottle, or a building panel.