Flame retardant polyolefin pallets and flame retardant master batch for their production

• US 6,849,677 B2
• Filed: 09/17/2002
• Issued: 02/01/2005
• Est. Priority Date: 09/17/2002
• Status: Active Grant

• Current Assignee: Rehrig Pacific Company
• Original Assignee: Rehrig Pacific Company
• Inventors: Overholt, Trenton M.
• Primary Examiner(s): Szekely, Peter
• Application Number:
  US10/244,994
• Publication Number:
  US 20040054052A1
• Time in Patent Office: 868 Days
• Field of Search: 523/351, 524/412, 524/464, 524/469, 524/437, 108/53.5, 108/53.7, 108/53.34, 108/57.12, 108901-902
• US Class Current: 524/412
• CPC Class Codes: C08K 2003/2227 of aluminium
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/2279 of antimony
• CPC Class Codes: C08L 23/02 not modified by chemical after-treatment
• CPC Class Codes: Y10S 108/901 Synthetic plastic industrial platform, e.g. pallet
• CPC Class Codes: Y10S 108/902 Made with deformable integral fastening elements

Abstract

Polyolefin-based pallets capable of passing standard pallet flammability tests are prepared by molding the pallet or one or more subassemblies thereof, of a polyolefin molding resin containing a flame retardant package containing a halogenated organic flame retardant, alumina trihydrate, and antimony trioxide. The flame retardants are advantageously supplied as a master batch at a concentration higher than that desired in the pallet or subassembly, in a polyolefin-compatible polymer.

Claims

1. A flame retardant molded polyolefin pallet comprising one or more subassemblies, at least one subassembly comprising a polyolefin containing a flame retardant package comprising as flame retardant components

a) 4-14% halogenated organic flame retardant,

b) 4-15% alumina trihydrate, and

c) 1-5% antimony trioxide, said percentages based on the weight of polyolefin and the sum of flame retardant components a) to c).

2. The pallet of claim 1 wherein the flame retardant components comprise

a) 7-12% halogenated organic flame retardant;

b) 8-12% alumina trihydrate;

c) 2-4% antimony trioxide; and

said percentages based on the weight of polyolefin and the sum of flame retardant components a) to c).

3. The pallet of claim 1, wherein subassemblies which comprise the most flammable portions of said pallet contain said flame retardant components.

4. The pallet of claim 1, wherein all of said subassemblies contain said flame retardant components.

5. The pallet of claim 1, wherein said polyolefin comprises polypropylene.

6. The pallet of claim 1, wherein said one or more subassemblies containing said fire retardant components further comprise a filler, fibrous reinforcement, or both filler and fibrous reinforcement.

7. The pallet of claim 1, further comprising one or more auxiliary flame retardants.

8. The pallet of claim 1, wherein said halogenated flame retardant comprises tetrabromobisphenol A.

16. A flame retardant polymer master batch suitable for addition to a polyolefin molding resin to prepare the pallet or subassembly thereof of claim 1, said master batch comprising 20 weight percent or more halogenated organic flame retardant, 20 weight percent or more of alumina trihydrate;

6 weight percent or more of antimony trioxide, and at least 10 weight percent of a polymer which is compatible with polyolefin in injection molding.

17. The master batch of claim 16, comprising 20 to 25% halogenated flame retardant, 20 to 40% alumina trihydrate, 6 to 15% antimony trioxide, and minimally 10% polyolefin-compatible polymer, said percentages being based on the total weight of the master batch.

18. The master batch of claim 16, comprising 25-35% halogenated organic flame retardant, 25-40% alumina trihydrate, and 8-12% antimony trioxide, balance polyolefin.

19. The master batch of claim 16 wherein said polyolefin comprises polypropylene.

20. The master batch of claim 16, wherein said halogenated organic flame retardant comprises tetrabromobisphenol A.

9. A process for the manufacture of a flame retardant polyolefin pallet or subassembly thereof, comprising

a) supplying a polyolefin molding resin

b) supplying a flame retardant package comprising flame retardant components

b)i) from 4-14% halogenated organic flame retardant;

b)ii) from 4-15% alumina trihydrate;

b)iii) from 1-5% antimony trioxide;

c) uniformly blending said polyolefin resin with the components b)i to b)iii of said flame retardant package to form a flame retardant-containing polyolefin molding resin; and

d) molding a polyolefin pallet or subassembly thereof from said flame retardant-containing polyolefin molding resin.

10. The process of claim 9, wherein said flame retardant components are supplied in a master batch of a polyolefin compatible polymer resin containing said flame retardant components in an amount higher than the amount desired in said pallet or subassembly thereof, and supplying sufficient polyolefin to reduce the level of said flame retardant components to the range of 4-14% a), 4-15% b), and 1-5% c).

11. The process of claim 9, wherein said pallet comprises at least a top deck and a bottom deck, optionally having a plurality of columns between said top deck and said bottom deck, at least one of said top deck, said bottom deck, or said columns being molded from a polymer of different flammability characteristics than another of said top deck, bottom deck, or columns.

12. The process of claim 11, comprising molding said top deck of said flame retardant-containing polyolefin molding resin.

13. The process of claim 11, further comprising constructing said top deck or a portion thereof of a non-polyolefin polymer which exhibits greater inherent flammability resistant characteristics than polyolefin.

14. The process of claim 9, wherein said polyolefin comprises polypropylene.

15. The process of claim 9, wherein said polyolefin pallet or subassembly thereof further contains a filler, fibrous reinforcement, or a mixture thereof.