Flame-retardant material, and preparation method therefor and product thereof

Abstract

Disclosed in the present application are a flame-retardant material, and a preparation method therefor and a product thereof. The flame-retardant material comprises a thermoplastic polymer, a reinforcing material, and a composite flame retardant, wherein the composite flame retardant comprises a phosphorus-containing flame retardant and a polysiloxane. The mass ratio of the thermoplastic polymer, the reinforcing material, the phosphorus-containing flame retardant, the polysiloxane, an antioxidant and a lubricant is (30-80):(10-50):(0.4-12):(2-20). The structural formula of the polysiloxane is: [(R1)2(R2)SiO1 / 2]a·[(R3)3SiO1 / 2]b·[SiO4 / 2]c, wherein (a+b):c = (0.4-1):1. The flame-retardant material disclosed in the present application can inhibit a dripping phenomenon during combustion under thin wall conditions, and achieves the thin-wall flame-retardant grade V-0.

Description

Flame retardant materials, their preparation methods and products Technical Field

[0001] This application relates to the field of materials, and in particular to a flame-retardant material capable of achieving a thin-walled flame-retardant rating of V0, a ​​method for preparing the flame-retardant material, and articles manufactured based on the flame-retardant material. Background Technology

[0002] Engineering plastics (e.g., thermoplastic polymers) are widely used in injection-molded products in the automotive, electronics, and other fields. Glass fiber can enhance the properties of thermoplastic polymers, achieving excellent characteristics such as high strength, high rigidity, high heat resistance, and good dimensional stability, thus finding widespread application in home appliances, consumer electronics, and medical devices. Among these, polycarbonate's self-charging ability and excellent ductility during combustion make it particularly suitable for the consumer electronics industry. However, the consumer electronics industry increasingly demands lighter and thinner designs that achieve their desired flame retardant ratings and often requires halogen-free products. Existing technologies typically use PTFE as an anti-dripping agent to achieve a V-0 rating. Per- and polyfluoroalkyl substances (PFAS) are considered permanent chemicals, persisting in the environment and virtually non-biodegradable, posing significant environmental hazards and accumulating in the food chain with potential health effects. In electronic devices, trends such as thinner designs and PFAS regulations place higher demands on the flame retardant properties of engineering plastics. How to achieve thin-walled flame retardancy without dripping under fluorine-free conditions has become an important problem to be solved. Summary of the Invention

[0003] To address the aforementioned problems, this application discloses a flame-retardant material, its preparation method, and articles obtained based on the flame-retardant material. The flame-retardant material can suppress dripping during combustion even in thin-walled conditions, achieving a flame-retardant rating of V-0 (0.6 mm).

[0004] The first aspect of this application discloses a flame-retardant material. The flame-retardant material may include: a thermoplastic polymer; a reinforcing material; and a composite flame retardant, including a phosphorus-containing flame retardant and a polysiloxane; wherein the mass ratio of the thermoplastic polymer, the reinforcing material, the phosphorus-containing flame retardant, and the polysiloxane is (30-80):(10-50):(4-12):(0.4-20); the structural formula of the polysiloxane can be represented as: [(R1)2(R2)SiO 1 / 2 ] a ·[(R3)3SiO 1 / 2 ] b ·[SiO 4 / 2 ] cR1, R2, and R3 may be the same or different, and each independently comprises an alkyl or substituted alkyl group containing no more than 30 carbon atoms, an alkenyl or substituted alkenyl group containing no more than 30 carbon atoms, an alkynyl or substituted alkynyl group containing no more than 30 carbon atoms, and / or an aryl or substituted aryl group containing no more than 30 carbon atoms. The relationship between a, b, and c satisfies (a+b):c = (0.4-1):1. This polysiloxane has a high silicon content, which easily transfers to the surface of polycarbonate resin in the early stages of combustion, forming a dense and stable silicon-containing carbon layer. This layer can both insulate against heat and oxygen, preventing further combustion reactions, and also prevent the leakage of combustibles from internal decomposition. The ratio of a, b, and c controls the network structure of the polysiloxane, achieving flame retardancy without reducing the mechanical properties of glass fiber reinforced polycarbonate. It forms a good synergistic effect with phosphorus-based flame retardants, achieving a thin-walled V-0 flame retardant rating in a fluorine-free formulation.

[0005] According to some embodiments of this application, the thermoplastic polymer may include a mixture of linear homopolymer carbonate and branched polycarbonate; the mass ratio of the linear homopolymer carbonate to the branched polycarbonate is (0.05-0.5):1; the melt index of the linear homopolymer carbonate is 1-40 g / 10 min, and the melt index of the branched polycarbonate is 2-15 g / 10 min. Traditional anti-dripping agent PTFE has a large molecular weight and, under the shear force of the screw, fibrouses to form a network structure, thereby preventing dripping. However, by combining branched and linear polycarbonate, a small amount of linear molecular chains are mixed into a large number of high-molecular-weight branched molecular chains (low melt index branched polycarbonate), causing the molecular chains to entangle and locally form a network structure, improving melt strength and reducing dripping during combustion. Furthermore, traditional anti-dripping agent PTFE is not environmentally friendly.

[0006] According to some embodiments of this application, the thermoplastic polymer may contain at least 30% recycled material.

[0007] According to some embodiments of this application, the reinforcing material may include one or more of glass fiber compositions, carbon fibers, and metal fibers. The carbon fibers may contain at least 30% recycled materials. Using recycled materials can conserve petrochemical resources and is environmentally friendly.

[0008] The glass fiber composition may comprise flat glass fibers and round glass fibers, with a mass ratio of flat glass fibers to round glass fibers of 1:(0.05-0.3); the flatness ratio of the flat glass fibers is 1:3-1:4, and the diameter of the round glass fibers is 7-13 micrometers. Thin-walled electronic devices have high requirements for the dimensions and flatness of the products. Due to its flat structure, flat glass fibers have a small difference in shrinkage rate between the flow direction and the vertical direction during injection molding, which can achieve a low warpage effect. However, its high fluidity can easily lead to dripping and ignition during combustion. Introducing a small amount of round glass fibers, interspersed among highly oriented flat glass fibers, hinders the rapid flow of PC resin melt along the flat glass fibers, avoiding the dripping and ignition phenomenon caused by this, while maintaining the original low warpage and mechanical properties of the flat glass fibers.

[0009] According to some embodiments of this application, the phosphorus-containing flame retardant may be selected from one or more phosphazene compounds and / or one or more phosphate ester compounds; wherein the mass ratio of the phosphazene compound to the phosphate ester compound is 1:(3-11).

[0010] According to some embodiments of this application, the phosphazene compound can be hexaphenoxycyclotriphosphazene, and the phosphate ester compound can be bisphenol A bis(diphenyl phosphate) and / or resorcinol bis(diphenyl phosphate). During combustion, an excessively long combustion time after flameout only achieves a V-1 rating, while also increasing the risk of drip ignition. Using phosphate ester compounds alone, the combustion time in thin-walled components easily exceeds 10 seconds. Introducing a small amount of phosphazene compound, through phosphorus-phosphorus compounding, can effectively reduce the combustion time and the probability of drip ignition.

[0011] According to some embodiments of this application, the structural formula of the polysiloxane is: [(CH3)2(CH2=CH)SiO 1 / 2 ] a ·[(CH3)3SiO 1 / 2 ] b ·[SiO 4 / 2 ] c .

[0012] According to some embodiments of this application, the flame retardant material may further include an antioxidant, which may include one or more of antioxidant 168, antioxidant 1010, and antioxidant 1098.

[0013] According to some embodiments of this application, the flame retardant material may further include a lubricant, which may include one or more of calcium stearate, stearic acid, ethylene bis-stearamide, pentaerythritol stearate, silicone powder, and polyethylene wax.

[0014] The second aspect of this application provides a method for preparing the flame-retardant material as described above. The preparation method may include: mixing the components in a mixing device according to the mass ratio of the components of the flame-retardant material to obtain a mixture; extruding the mixture into strips using an extrusion device and transferring them to a granulation device for granulation; and obtaining the flame-retardant material after post-processing.

[0015] A third aspect of this application provides an article of manufacture which can be made of the flame-retardant material described above.

[0016] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Detailed Implementation

[0017] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0018] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The terms “comprising” or “including” and similar terms used herein mean that an element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. The terms “and / or” or “and / or” as used herein include any and all combinations of one or more of the associated listed items.

[0019] The flame-retardant material disclosed in this application achieves a flame-retardant rating of V-0 (0.6 mm) by using a combination of thermoplastic polymers with excellent anti-dripping properties, glass fibers, and composite flame retardants to suppress dripping during combustion in thin-walled conditions. Furthermore, the flame-retardant material disclosed in this application does not contain anti-dripping agents and its components are halogen-free (especially fluorine-free), ensuring high performance while being environmentally friendly.

[0020] The following describes some preferred embodiments of this application. It should be noted that the following description is for illustrative purposes only and is not intended to limit the scope of protection of this application. The steps involved in this application may be performed precisely in sequence, or various steps may be processed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more steps may be removed from these processes.

[0021] This application discloses a flame-retardant material that can be composed of a glass fiber reinforced thermoplastic polymer combined with a composite flame retardant (the composite flame retardant is a composition of a phosphorus-based flame retardant and a polysiloxane).

[0022] Thermoplastic polymers may include combinations of one or more substances, such as mixtures of one or more of polyethylene (PE), polypropylene (PP), polystyrene (PS), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polyamide (PA), polycarbonate (PC), polyetheretherketone (PEEK), etc. These polymers may also be homopolymers (e.g., linear polymers, branched / hyperbranched polymers, etc.) or copolymers (e.g., random copolymers, alternating copolymers, periodic copolymers, statistical copolymers, block copolymers, regular block copolymers, stereoblock copolymers, graded copolymers, and / or graft copolymers, etc.). A suitable, but not limiting, thermoplastic polymer may be polycarbonate. For example, the polycarbonate may be bisphenol A type polycarbonate (BPA-PC), bisphenol S type polycarbonate (BPS-PC), bisphenol TMC type polycarbonate, aliphatic polycarbonate, aromatic-aliphatic copolycarbonate, poly(1,4-cyclohexanediethanol) carbonate (PCHC), silicon-containing polycarbonate, poly(hydroquinone) carbonate, poly(resorcinol) carbonate, poly(2,2,4,4-tetramethyl-1,3-cyclobutanediol) carbonate, phosphorus-containing polycarbonate, etc.

[0023] In some embodiments, the polycarbonate may be prepared based on bisphenol compounds. Suitable but non-limiting bisphenol compounds may include 2,2-bis(4-hydroxyphenyl)propane (bisphenol A), 4,4'-dihydroxydiphenyl sulfone (bisphenol S), bis(4-hydroxyphenyl)methane (bisphenol F), 1,1-bis(4-hydroxyphenyl)cyclohexane (bisphenol Z), 1,1-bis(4-hydroxyphenyl)-4-isopropylcyclohexane (bisphenol C), 1,1-bis(4-hydroxyphenyl)-1-phenylethane (bisphenol AP), 4,4'-(1,3-phenyldiisopropyl)diphenol (bisphenol M), 4,4'-(1,4-phenyldiisopropyl)diphenol (bisphenol P), 1,1-bis(4-hydroxyphenyl)-1 ...4'-bis(4-hydroxyphenyl)-1-isopropylcyclohexane (bisphenol S), 1,4'-bis(4-hydroxyphenyl)-1-isopropylcyclohexane (bisphenol S), 1,4'-bis(4-hydroxyphenyl)-1-isopropylcyclohexane (bisphenol A), 1,4'-bis(4-hydroxyphenyl)-1-isopropylcyclohexane (bisphenol S), 1,4'-bis(4-hydroxyphenyl)-1-isopropylcyclohexane (bisphenol A), 1,4'-bis(4-hydroxyphenyl)-1-isopropylcyclohexane (bisphenol B), 1,4'-bis(4-hydroxyphenyl)-1-isopropylcyclohexane (bisphenol A), 1,4 4,4'-Dihydroxybiphenyl, 2,2'-Dihydroxybiphenyl, 3,3'-Dihydroxybiphenyl, 4,4'-Dihydroxydiphenyl ether, 3,3'-Dihydroxydiphenyl ether, 4,4'-Dihydroxydiphenylmethane, 2,2'-Dihydroxydiphenylmethane, 4,4'-Dihydroxydiphenylethane, 4,4'-Dihydroxydiphenylpropane, 4,4'-Dihydroxydiphenylbutane, 4,4'-Dihydroxydiphenylpentane, 4,4'-Dihydroxydiphenylhexane, 4,4'-Dihydroxydiphenylheptane, 4,4'-Dihydroxydiphenyloctane, 4,4'-Dihydroxydiphenylnonane, 4 4'-Dihydroxydiphenyldecane, 1,4-Dihydroxynaphthalene, 1,5-Dihydroxynaphthalene, 2,6-Dihydroxynaphthalene, 2,7-Dihydroxynaphthalene, 1,1-bis(4-hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)cycloheptane, 1,1-bis(4-hydroxyphenyl)cyclooctane, 9,9-bis(4-hydroxyphenyl)fluorene, 4,4'-Dihydroxydiphenyl sulfone, 3,3'-Dihydroxydiphenyl sulfone, 4,4'-Dihydroxydiphenyl sulfide, 3,3'-Dihydroxydiphenyl sulfide, 4,4'-Dihydroxydiphenyl sulfide, 4,4'-Dihydroxydiphenyl ketone, 2,2'-Dihydroxydiphenyl ketone Ketones, 4,4'-dihydroxyphenylethylene, 4,4'-dihydroxydiphenylacetylene, 4,4'-dihydroxydiphenylaldehyde, 4,4'-dihydroxydiphenylmethanol, 4,4'-dihydroxydiphenylethanol, 4,4'-dihydroxydiphenylpropanol, 4,4'-dihydroxydiphenylbutanol, 4,4'-dihydroxydiphenylpentanol, 4,4'-dihydroxydiphenylhexanol, 4,4'-dihydroxydiphenylheptanol, 4,4'-dihydroxydiphenyloctanol, 4,4'-dihydroxydiphenylnonanol, 4,4'-dihydroxydiphenyldecanol, 4,4'-dihydroxydiphenylthione, 4,4'-dihydroxydiphenylsulfone ketone, 4,4'-dihydroxydiphenylsulfone ether, etc. 3,3-bis(4-hydroxyphenyl)benzopyrrolidone, 2-phenyl-3,3-bis(4-hydroxyphenyl)benzopyrrolidone, etc. The functional groups, such as alkyl groups, contained in the above bisphenol compounds may also contain heteroatoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, etc.

[0024] In some embodiments, the polycarbonate can be obtained based on bisphenol A. For example, bisphenol A polycarbonate is obtained by interfacial polycondensation of bisphenol A and phosgene in a two-phase system. Exemplary steps may include dissolving bisphenol A in an aqueous sodium hydroxide solution, mixing the solution with an organic solvent containing phosgene (e.g., dichloromethane, 1,2-dichloroethane, chlorobenzene, toluene, etc.), conducting a polycondensation reaction at the two-phase interface under stirring, separating the organic phase after the reaction, washing and drying, and evaporating the solvent to obtain bisphenol A polycarbonate. Subsequent optional polycondensation can yield polymers with higher molecular weights. Of course, melt transesterification polycondensation or non-phosgene melt transesterification polycondensation can also be used to obtain bisphenol A polycarbonate. During the preparation of the polycarbonate, end-capping agents can also be used to control and improve the molecular weight and properties of the polymer. Compounds such as monophenols (e.g., phenol, p-tert-butylphenol, p-isooctylphenol, p-dodecylphenol, p-phenylphenol, etc., are used to improve stability and heat resistance), phenolic compounds (e.g., 2,4-di-tert-butylphenol, 2,6-di-tert-butyl-4-methylphenol (BHT), 2,6-di-tert-butylphenol, etc., are used to improve thermal stability, enhance antioxidant properties, and improve resistance to yellowing), and esters (e.g., p-tert-butylbenzoic acid, methyl p-tert-butylbenzoate, benzoic acid, methyl benzoate, etc., are used to improve hydrolysis resistance and improve thermal stability) Qualitative and long-chain alkylphenol compounds (such as nonylphenol, dodecylphenol, octadecylphenol, etc., used to improve weather resistance), epoxy compounds (such as phenyl glycidyl ether, p-tert-butylphenyl glycidyl ether, etc., used to improve weather resistance and hydrolysis resistance), phosphate ester compounds (such as triphenyl phosphate, tris(2,6-dimethylphenyl) phosphate, etc., used to improve flame retardancy and increase thermal stability), and multifunctional compounds (such as methyl 4-hydroxybenzoate, 4-hydroxyacetophenone, etc., used to provide multiple functionalities) can be used as end-capping agents. In addition, thioether carbonyl end-capping agents as shown in formula GC(=O)-LSR can also be used. Here, G represents a leaving group, which is usually a hydroxyl (-OH) or other reactive group, and L can be C1-C2. 12 Aliphatic or aromatic linking groups, such as alkyl or aryl groups, where R can be C1-C. 30 Alkyl or aryl. Suitable, but not limiting, the thioether carbonyl end-capping agent may include, but is not limited to, 2-mercaptobenzoic acid, thiosalicylic acid, S-(4-hydroxyphenyl)thioacetic acid, 2-(phenylthio)acetic acid, methyl 4-mercaptobenzoate, 3,3'-thiobis(2-methylpropionic acid), 2-[(4-hydroxyphenyl)thio]benzoic acid, 4-(methylthio)benzoic acid, 2-mercapto-5-methylbenzoic acid, S-phenylthioacetic acid, etc., or any combination thereof.

[0025] In some embodiments, the polycarbonate may be a composition of linear homopolymer and branched polycarbonate. The interfacial polycondensation and melt polycondensation methods described above can be used to prepare the linear homopolymer. The branched polycarbonate can be prepared by adding a monomer having three or more functional groups (or a multifunctional monomer) during the synthesis of the polycarbonate (e.g., using interfacial polycondensation). Generally, the amount of this multifunctional monomer added is usually less than 5 mol% to avoid gelation. Alternatively, branching points can be introduced by subsequent reactions at the hydroxyl groups at the ends of the linear polycarbonate chains to obtain branched polycarbonate. The aforementioned multifunctional monomer can then be used as a modifier to react with the hydroxyl groups to form a branched structure. Alternatively, a multifunctional monomer can be added to molten polycarbonate to allow it to mix and react with the polycarbonate to obtain branched polycarbonate. Alternatively, a precursor of the multifunctional monomer can be added to the polymerization reaction to generate a multifunctional monomer during the reaction, which then participates in the polymerization reaction to make the branching point distribution of the branched polycarbonate more uniform. Alternatively, high-energy radiation can be used to induce cross-linking and branching of polycarbonate molecular chains to synthesize branched polycarbonates. For example, under controlled conditions, linear polycarbonates can be irradiated with gamma rays or electron beams to form branched structures through free radical reactions. Exemplary branching agents may include, but are not limited to, polyfunctional phenolic compounds such as 1,3,5-trihydroxybenzene, tetra(4-hydroxyphenyl)methane, 1,1,1-tris(4-hydroxyphenyl)ethane, phloroglucinol, and hydroquinone; polyfunctional carboxylic acid compounds such as tricarboxybenzoic acid, citric acid, 1,2,3,4-butanetetracarboxylic acid, trimellitic anhydride, and pyromellitic tetracarboxylic acid; polyfunctional amine compounds such as diethylenetriamine, triethylenetetramine, melamine, and m-phenylenediamine; and polyfunctional isocyanate compounds such as triisocyanates (e.g., triglycidyl isocyanate) and polymethyl polyphenyl polyisocyanate (PAPI). Multifunctional epoxy compounds include triglycidyl isocyanurate, phenolic epoxy resin, and tetrafunctional epoxy resin; multifunctional acid anhydrides include pyromellitic dianhydride, trimellitic anhydride, and bismaleic anhydride; multifunctional alkenes include triallyl isocyanurate and pentaerythritol tetraacrylate; inorganic multifunctional compounds include multifunctional silanes (such as tetraethoxysilane), polysiloxanes, and multifunctional phosphides; reactive oligomers include epoxidized polybutadiene, hydroxyl-terminated polybutadiene, and multifunctional polyethers; and in-situ generated multifunctional compounds include phenolic resin formed by the reaction of formaldehyde and phenols, and hydrolysis products of multifunctional silanes.

[0026] Branching agents used in the synthesis of branched polycarbonates may include, but are not limited to, 1,1,1-tris(4-hydroxyphenyl)ethane, tetra(4-hydroxyphenyl)methane, 1,3,5-trihydroxybenzene, 4,4',4”-trihydroxytriphenylmethane, phloroglucinol, hydroquinone, 2,4,6-trimethyl-2,4,6-tris(4-hydroxyphenyl)heptane-3-one, 1,3,5-tris(2-hydroxyethyl)isocyanuric acid, trimethylolpropane, pentaerythritol, dipentaerythritol, trimethylolpropane triglycidyl ether, triglycidyl isocyanurate, trihydroxybenzoic acid, 1,3,5-tris(4-hydroxyphenyl)benzene, 4,4'-di(4-hydroxyphenyl)valerate, 4,6-dimethyl-2,4,6-tris(4-hydroxyphenyl)-2-heptene, 1,1,2,2-tetra(4-hydroxyphenyl)ethane, 1, 4-Di(4',4”-Dihydroxytriphenylmethyl)benzene, 2,2-bis(4-hydroxy-3,5-dimethylphenyl)propane, 4,4'-di(3,5-dimethyl-4-hydroxyphenyl)methane, 1,3-di(4-hydroxyphenyl)-5,5-dimethylhydantoin, tris(4-hydroxyphenyl)phosphate, 1,3,5-tris(4-hydroxyphenoxy)benzene, 4,4',4”-trihydroxyphenyl ether, 2,4,6-tris(2,4-dihydroxyphenyl)-1,3,5-triazine, 1,1,3-tris(4-hydroxyphenyl)propane, 1,3,5-tris(4-hydroxy-3-methylphenyl)-1,3,5-triazine-2,4,6(1H,3H,5H)-trione, 4,4'-bis(4,4'-dihydroxytriphenylmethyl)biphenyl, tris(4-hydroxyphenyl)cyanomethane, etc., or any combination thereof.

[0027] In some embodiments, the mass ratio of the linear homopolymer carbonate to the branched carbonate can be (0.05-0.5):1. Optionally or preferably, the mass ratio of the linear homopolymer carbonate to the branched carbonate can be (0.1-0.5):1. Optionally or preferably, the mass ratio of the linear homopolymer carbonate to the branched carbonate can be (0.2-0.4):1. Optionally or preferably, the mass ratio of the linear homopolymer carbonate to the branched carbonate can be (0.25-0.35):1. Alternatively, the mass ratio of the linear homopolymer carbonate to the branched carbonate can be any value within the above ranges, for example, 0.05:1, 0.08:1, 0.17:1, 0.5:1, etc.

[0028] When selecting a mixture of linear and branched polycarbonate as the thermoplastic polymer, the melt flow index (MFR) can be used for material selection. For example, the melt flow index of the linear homopolymer can be 1-40 g / 10 min, such as 1 g / 10 min, 5 g / 10 min, 10 g / 10 min, 15 g / 10 min, 20 g / 10 min, 25 g / 10 min, 30 g / 10 min, 35 g / 10 min, 40 g / 10 min, etc. The melt index of the branched polycarbonate can be 2-15 g / 10 min, for example, 2 g / 10 min, 3 g / 10 min, 4 g / 10 min, 5 g / 10 min, 6 g / 10 min, 7 g / 10 min, 8 g / 10 min, 9 g / 10 min, 10 g / 10 min, 11 g / 10 min, 12 g / 10 min, 13 g / 10 min, 14 g / 10 min, 15 g / 10 min, etc. An exemplary but non-limiting choice is that the melt index of the linear homopolymer is 2 g / 10 min or 36 g / 10 min, and the melt index of the branched polycarbonate is 3 g / 10 min or 12 g / 10 min. For this melt index, the test conditions can be performed under a pressure of 1.2 kg at 300 °C. In this application, the selection of the melt index of the linear polycarbonate and the branched polycarbonate has an impact on the performance of the flame-retardant material. The aforementioned limitation on the melt flow index enables the flame retardant material to have superior performance, rather than being chosen arbitrarily.

[0029] Molecular weight can also be used as a selection criterion. For example, the molecular weight of the linear homopolymer carbonate can be in the range of 15,000-30,000 Daltons, or 17,000-28,000 Daltons, or 19,000-25,000 Daltons, or 21,000-22,000 Daltons. The molecular weight of the branched polycarbonate can be in the range of 30,000-45,000 Daltons, or 32,000-40,000 Daltons, or 34,000-38,000 Daltons, or 35,000-36,000 Daltons.

[0030] The mass fraction of polycarbonate in the flame retardant material, which is composed of a mixture of linear homopolymer and branched polycarbonate, can be 30-80 wt%. Optionally or preferably, the mass fraction of polycarbonate in the flame retardant material can be 40-70 wt%. Optionally or preferably, the mass fraction of polycarbonate in the flame retardant material can be 50-60 wt%. Alternatively, the mass fraction of polycarbonate in the flame retardant material can be any value within the above range, such as 64.4 wt%, 68.4 wt%, etc.

[0031] In some embodiments, the polycarbonate may also be a linear homopolymer or a branched polycarbonate, and its related properties / characteristics may be as described above.

[0032] In some embodiments, the polycarbonate may include at least 30% recycled material. For example, 30%, 33%, 35%, 37%, 40%, 50%, and even more. Using recycled material is not only economical but also environmentally friendly.

[0033] The reinforcing material can be used to enhance the properties of the thermoplastic polymer, including but not limited to material strength / stiffness / toughness, heat resistance, etc. For example, the reinforcing material can be melt-blended with the thermoplastic polymer, such as the aforementioned polycarbonate, to obtain a reinforced polycarbonate material. In some embodiments, the reinforcing material may include one or more of glass fibers, carbon fibers, mineral fillers, glass beads, carbon nanotubes, aramid fibers, carbon black, metal powders, metal fibers, etc. For example, glass fibers (a composition composed of a single type of glass fiber or multiple types of glass fibers) can be used to improve the strength, stiffness, and dimensional stability of thermoplastic polymers such as polycarbonate. Similarly, carbon fibers and / or carbon nanotubes can also improve the strength and thermal properties of thermoplastic polymers such as polycarbonate. Furthermore, metal fibers (e.g., stainless steel, copper, aluminum, nickel, chromium, etc.) have the same / similar effects. Other fillers, such as talc, can improve stability; mica can increase rigidity and heat resistance; kaolin can increase hardness; and others, such as calcium carbonate, dolomite, wollastonite, barium sulfate, silica, feldspar, and barite, can also participate in reinforcing the thermoplastic polymer to improve the performance of the flame retardant material.

[0034] In some embodiments, when carbon fiber is used as the reinforcing material, the carbon fiber may include at least 30% recycled material. For example, 30%, 33%, 35%, 37%, 40%, 50%, and even more. Using recycled material is not only economical but also environmentally friendly.

[0035] In some embodiments, the reinforcing material may be a glass fiber composition. The term "glass fiber" may be considered an abbreviation for "glass fiber" in this application. In some embodiments, the glass fiber composition may include flat glass fibers and round glass fibers. Flat glass fibers may have an elliptical or near-elliptical cross-section, and round glass fibers may have a solid circular or annular cross-section. Materials such as silica sand (providing silica), feldspar (providing alumina and potassium oxide), dolomite (providing magnesium oxide and calcium oxide), limestone (providing calcium oxide), borax, or boric acid (providing boron oxide), combined with soda ash, sodium sulfate, zirconium oxide, titanium oxide, iron oxide, lithium oxide, zinc oxide, etc., can be used to prepare the aforementioned glass fibers. Different glass fibers, such as E-glass fibers, S-glass fibers, C-glass fibers, etc., can be obtained by adjusting the selection and proportion of raw materials. The glass fibers used in this application can be selected based on relevant physical properties. For example, for flat glass fibers, the aspect ratio can be 1:3-1:4, such as 1:3, 1:3.1, 1:3.2, 1:3.3, 1:3.4, 1:3.5, 1:3.6, 1:3.7, 1:3.8, 1:3.9, 1:4, or any value within the above range. Optionally, the aspect ratio can be 1:3 or 1:4. For circular glass fibers, the diameter can be 7-13 micrometers, such as 7 micrometers, 8 micrometers, 9 micrometers, 10 micrometers, 11 micrometers, 12 micrometers, 13 micrometers, or any value within the above range. Optionally, the diameter can be 7 micrometers, 10 micrometers, 13 micrometers, etc.

[0036] In the glass fiber composition, the mass ratio of the flat glass fiber to the round glass fiber is 1:(0.05-0.3). Optionally or preferably, the mass ratio of the flat glass fiber to the round glass fiber is 1:(0.1-0.3). Optionally or preferably, the mass ratio of the flat glass fiber to the round glass fiber is 1:(0.15-0.25). Optionally or preferably, the mass ratio of the flat glass fiber to the round glass fiber is 1:(0.18-0.22). Alternatively, the mass ratio of the flat glass fiber to the round glass fiber can be any value within the above-mentioned numerical range, for example, 1:0.176, 1:0.333, etc.

[0037] The composite flame retardant can be composed of a phosphorus-containing flame retardant and a polysiloxane. The phosphorus-containing flame retardant may include one or more phosphazene compounds and / or one or more phosphate ester compounds. Phosphazene compounds can be inorganic or organic-inorganic hybrids containing phosphazene groups (-P=N-) within their molecules. In this application, the general structural formula of the phosphazene compound can be (NPX2). nThe notation is as follows: N represents a nitrogen atom, P represents a phosphorus atom, X represents a substituent group, such as halogen, amino, substituted or unsubstituted alkyl, substituted or unsubstituted aryl, etc., and n represents the number of repeating units, which can be 3 or a larger integer. Examples of suitable mono-non-limiting phosphazene compounds may include hexa(dimethylamino)cyclotriphosphazene [NP(N(CH3)2)2]3, hexaphenylcyclotriphosphazene (NPPh2)3, hexa(diethylamino)cyclotriphosphazene [NP(N(C2H5)2)2]3, hexa(morpholinyl)cyclotriphosphazene [NP(NC4H8O)2]3, and hexa(piperidinyl)cyclotriphosphazene [NP(NC5H]3, 2, 3, 4, 5, 6, 7, 8, 9, 1 ... 10 )2]3, hexa(p-tolyl)cyclotriphosphazene [NP(p-CH3C6H4)2]3, hexa(methoxy)cyclotriphosphazene [NP(OCH3)2]3, hexa(ethoxy)cyclotriphosphazene [NP(OC2H5)2]3, hexa(isopropoxy)cyclotriphosphazene [NP(OCH(CH3)2)2]3, hexa(tert-butoxy)cyclotriphosphazene [NP(OC(CH3)3)2]3, hexa(cyano)cyclotriphosphazene [NP(CN)2]3, hexa(nitro)cyclotriphosphazene [NP(NO2)2]3, hexa(amino)cyclotriphosphazene [NP(NH2)2]3, hexa(acetamido)cyclotriphosphazene [NP(NHCOCH3)2]3, hexa(phenoxy)cyclotriphosphazene [NP(OC6H5)2]3, hexa(phenylthio)cyclotriphosphazene [NP(SC6H5)2]3, etc. In some embodiments, the phosphazene compound is hexa(phenoxy)cyclotriphosphazene.

[0038] The phosphate ester compounds can be represented by O=P(OR)3. Here, O represents an oxygen atom, P represents a phosphorus atom, and R represents hydrogen or an organic group, including substituted or unsubstituted alkyl, aryl, etc. Examples of suitable single-non-limiting phosphate ester compounds may include triphenyl phosphate, trimethylbenzyl phosphate, tris(2-ethylhexyl) phosphate, tris(2-butoxyethyl) phosphate, dimethyl resin phosphate, bisphenol A bis(diphenyl phosphate), resorcinol bis(diphenyl phosphate), tris(4-isopropylphenyl) phosphate, tris(2,4-di-tert-butylphenyl) phosphate, tris(4-isopropylphenyl) phosphate, tris(2,6-dimethylphenyl) phosphate, etc. Tris(4-tert-butylphenyl) phosphate, tris(2-ethoxyethyl) phosphate, tris(2-methoxyethyl) phosphate, tris(2-propenyl) phosphate, tris(2-propynyl) phosphate, tris(4-bromophenyl) phosphate, tris(3,5-dimethylphenyl) phosphate, tris(2,4,6-trimethylphenyl) phosphate, tris(2-hydroxypropyl) phosphate, tris(2-propenyloxyethyl) phosphate, tris(2-cyanoethyl) phosphate, tris(2-carboxyethyl) phosphate, etc. In some embodiments, the phosphate compound is bisphenol A bis(diphenyl phosphate) and / or resorcinol bis(diphenyl phosphate).

[0039] In some embodiments, the phosphazene compound and the phosphate ester compound can be used alone as flame retardants, or a mixture of the two compounds can be used as flame retardants. When the phosphorus-containing flame retardant uses a mixture of the phosphazene compound and the phosphate ester compound, the mass ratio of the phosphazene compound to the phosphate ester compound is 1:(3-11). Optionally or preferably, the mass ratio of the phosphazene compound to the phosphate ester compound is 1:(4-10). Optionally or preferably, the mass ratio of the phosphazene compound to the phosphate ester compound is 1:(5-9). Optionally or preferably, the mass ratio of the phosphazene compound to the phosphate ester compound is 1:(6-8). Alternatively, the mass ratio of the phosphazene compound to the phosphate ester compound can be any value within the above range, for example, a mass ratio of 1:5, 1:6, 1:7, etc.

[0040] In some embodiments, the phosphorus-containing flame retardant may also be other flame retardants, such as phosphate compounds such as tributyl phosphate, disodium hexametaphthalate (POT), trisodium hexametaphthalate (TSP), phosphonate compounds, organophosphate compounds, phosphorus heterocyclic compounds and polymeric phosphonate compounds, ammonium polyphosphate compounds, and organosphinic acid metal salt compounds.

[0041] The proportion (or mass percentage) of the phosphorus-containing flame retardant in the total mass of the flame-retardant material can be 2-20%. Optionally or preferably, the mass percentage of the phosphorus-containing flame retardant can be 3-16%. Optionally or preferably, the mass percentage of the phosphorus-containing flame retardant can be 4-12%. Optionally or preferably, the mass percentage of the phosphorus-containing flame retardant can be 5-10%. Optionally or preferably, the mass percentage of the phosphorus-containing flame retardant can be 6-8%. Alternatively, the mass percentage of the phosphorus-containing flame retardant can be any value within the numerical range described above, for example, 6%, 7%, 8%, 9%, 10%, 12%, 15%, etc.

[0042] The polysiloxane used in this application can be of the general structural formula: [R 1 SiO 3 / 2 ] A [R 2 R 3 SiO] B [R 4 R 5 R 6 SiO 1 / 2 ] C Indicated. Among them, R 1 R 2 R 3 R 4 R 5 R 6 These can represent the same or different organic groups, including substituted or unsubstituted alkyl, alkenyl, alkynyl, cyclic hydrocarbon, aryl, etc. When a group is substituted, it can be replaced by a polyfunctional group consisting of heteroatoms (e.g., oxygen, nitrogen, sulfur, etc.), hydroxyl groups, alkoxy groups, etc., or multiple groups thereof.

[0043] The alkyl group can have a variety of suitable structures. Some suitable alkyl groups can be unbranched and / or straight-chain functional groups, while some suitable alkyl groups can be branched and / or branched functional groups. Branched alkyl groups and / or branched alkyl groups can be branched and connected at a single position or at multiple positions. For example, it can include two or more branches of equal length and / or two or more branches of unequal length. Some exemplary examples include, but are not limited to, methyl, ethyl, n-propyl, isopropyl, butyl, isobutyl, tert-butyl, sec-butyl, n-pentyl, isopentyl, neopentyl, 2-methylbutyl, 3-methylbutyl, 2,2-dimethylpropyl, n-hexyl, 2-methylpentyl, 3-methylpentyl, 4-methylpentyl, 2,3-dimethylbutyl, 2-ethylbutyl, 3-ethylpentyl, etc. The above alkyl groups can also be substituted, for example, by substitution of heteroatoms that are non-halogenated, particularly fluorine atoms.

[0044] Similarly, the alkenyl and alkynyl groups can also be unbranched and / or straight-chain functional groups, or branched and / or hyperbranched. For alkenyl and alkynyl groups, they can also be branched or connected at a single or multiple positions. When branched at multiple positions, the branches can be equally spaced or unequally spaced.

[0045] Exemplary alkenyl groups may include, but are not limited to, vinyl, 1-propenyl, 2-butenyl, isobutenyl, 2-pentenyl, 2-methyl-1-propenyl, hexenyl, 2-methyl-2-pentenyl, 4-methyl-2-pentenyl, heptenyl, 2-heptenyl, etc. Exemplary alkynyl groups may include, but are not limited to, ethynyl, 1-propynyl, 2-butynyl, 3-pentynyl, 4-hexynyl, 3-methyl-1-butynyl, 4-methyl-1-pentynyl, 3,3-dimethyl-1-butynyl, 4-ethyl-1-hexynyl, 4-isopropyl-1-pentynyl, 3,4-dimethyl-1-pentynyl, etc.

[0046] The cyclic hydrocarbon group can be obtained by cyclizing the above-mentioned straight-chain hydrocarbon group. Some exemplary examples may be cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, methylcyclopropyl, ethylcyclobutyl, dimethylcyclohexyl, cyclohexenyl, cyclopentadienyl, cyclooctatetraenyl, bicyclo[2.2.1]heptyl, bicyclo[2.2.2]octyl, adamantyl (tricyclo[3.3.1.13,7]decyl), 1-methylcyclopentyl, 2-ethylcyclohexyl, 4-isopropylcyclohexyl, cycloheptenyl, etc.

[0047] Suitable aryl groups may include phenyl groups, or functional groups constructed with phenyl as the basic structure. One non-limiting example is a fused-ring aryl group obtained by fusion of multiple phenyl groups; another non-limiting example is a substituted phenyl group, where the substituted functional group may include unsubstituted and / or substituted hydrocarbon groups, aryl groups, nitro groups, alkoxy groups, etc. Some exemplary examples include, but are not limited to, phenyl, naphthyl, anthraceneyl, phenanthrene, methylphenyl, p-tolyl, m-tolyl, o-tolyl, ethylphenyl, p-ethylphenyl, m-ethylphenyl, o-ethylphenyl, propylphenyl, isopropylphenyl, tert-butylphenyl, nitrophenyl, aminophenyl, dimethylaminophenyl, cyanophenyl, methoxyphenyl, ethoxyphenyl, formylphenyl, vinylphenyl, etc.

[0048] It should be noted that the examples above are for illustrative purposes only and are not intended to limit the scope of protection of this application. Any modifications / adjustments / updates made based on the teachings of this application are within the scope of protection of this application.

[0049] The alkyl and aryl groups described in this application can have various suitable lengths and spatial structures, described by the number of carbon atoms they contain. The alkyl, alkenyl, alkynyl, cycloalkyl, and aryl groups can each independently contain less than or equal to 30 carbon atoms, less than or equal to 28 carbon atoms, less than or equal to 26 carbon atoms, less than or equal to 24 carbon atoms, less than or equal to 22 carbon atoms, less than or equal to 20 carbon atoms, less than or equal to 18 carbon atoms, less than or equal to 16 carbon atoms, less than or equal to 14 carbon atoms, less than or equal to 12 carbon atoms, less than or equal to 10 carbon atoms, less than or equal to 8 carbon atoms, less than or equal to 6 carbon atoms, less than or equal to 4 carbon atoms, less than or equal to 3 carbon atoms, less than or equal to 2 carbon atoms, or 1 carbon atom. Of course, other ranges are also permitted.

[0050] Regarding the aforementioned general structural formula of polysiloxanes, it includes three basic structural units that constitute polysiloxanes: T unit (R 1 SiO 3 / 2 Trifunctional unit), D unit (R) 2 R 3 SiO (difunctional unit) and M unit (R 4 R 5 R 6 SiO 1 / 2 (Monofunctional unit). A, B, and C represent the number of repetitions of each unit. The numerical selection of A, B, and C allows for the inclusion of different types / categories of polysiloxanes in the composition of the flame-retardant material.

[0051] In some embodiments, the polysiloxane may be modified. For example, elements such as phosphorus, nitrogen, boron, aluminum, zirconium, and titanium may be introduced to improve performance. Alternatively, the polysiloxane may include copolymers combined with other polymers, such as polydimethylsiloxane-polyphenylmethylsiloxane copolymers, polydimethylsiloxane-polyethylene copolymers, polydimethylsiloxane-polyacrylate copolymers, polydimethylsiloxane-polyurethane copolymers, polydimethylsiloxane-polystyrene copolymers, polydimethylsiloxane-polymethyl methacrylate copolymers, polydimethylsiloxane-polyethylene glycol copolymers, polydimethylsiloxane-polyvinylpyrrolidone copolymers, polydimethylsiloxane-polyacrylonitrile copolymers, and polydimethylsiloxane-polyacrylonitrile copolymers. Polydimethylsiloxane-polylactic acid copolymers, polydimethylsiloxane-polycaprolactone copolymers, polydimethylsiloxane-polycarbonate copolymers, polydimethylsiloxane-polyvinyl alcohol copolymers, polydimethylsiloxane-polyacrylamide copolymers, polydimethylsiloxane-hydroxyethyl methacrylate copolymers, polydimethylsiloxane-polyvinylpyridine copolymers, polydimethylsiloxane-ethylene oxide copolymers, polydimethylsiloxane-polybutadiene copolymers, polydimethylsiloxane-polyisobutylene copolymers, polydimethylsiloxane-polyacrylic acid copolymers, and polydimethylsiloxane-polymethacrylic acid copolymers, etc. These copolymers combine the properties of polysiloxanes with those of other polymers to achieve a variety of unique properties, better meeting requirements.

[0052] In some implementations, the polysiloxane may have the following structural formula: [(R1)2(R2)SiO 1 / 2 ] a ·[(R3)3SiO 1 / 2 ] b ·[SiO 4 / 2 ] c Where R1, R2, and R3 can be the same as those described above. 1 To R 6The terms a, b, and c are, respectively, alkyl or substituted alkyl groups containing no more than 30 carbon atoms, alkenyl or substituted alkenyl groups containing no more than 30 carbon atoms, alkynyl or substituted alkynyl groups containing no more than 30 carbon atoms, and / or aryl or substituted aryl groups containing no more than 30 carbon atoms. The relationships (a+b):c = (0.4-1):1 can be satisfied between a, b, and c. For example, (a+b):c = 0.4:1, or 0.5:1, or 0.6:1, or 0.7:1, or 0.8:1, or 0.9:1, or 1:1, etc. Alternatively, the relationships between a, b, and c can be (a+b):c = 0.68:1, 0.4:1, 1:1, etc. The polysiloxane associated with this relationship has a high silicon content, which easily migrates to the surface of polycarbonate resin in the early stages of combustion, forming a dense and stable silicon-containing carbon layer. This layer not only provides thermal and oxygen insulation to block further combustion reactions but also prevents the leakage of combustibles from internal decomposition. The ratio of a, b, and c controls the network structure of the polysiloxane, achieving flame retardancy without reducing the mechanical properties of glass fiber reinforced polycarbonate. In some embodiments, the polysiloxane may be methylvinylsiloxane, with the structural formula: [(CH3)2(CH2=CH)SiO 1 / 2 ] a ·[(CH3)3SiO 1 / 2 ] b ·[SiO 4 / 2 ] c .

[0053] When participating in the formation of the flame-retardant material, the polysiloxane accounts for 0.4-20% of the total mass of the flame-retardant material, for example, 0.4%, 1%, 2%, 5%, 7%, 9%, 12%, 15%, 20%, etc. In some embodiments, the polysiloxane accounts for 0.4%, 4%, 5%, 20% of the total mass of the flame-retardant material, etc.

[0054] In some embodiments, the polysiloxane may be replaced with other flame retardants to form the composite flame retardant with the phosphorus-containing flame retardant. For example, it may be other polymers such as microporous foamed polypropylene (MPP) or inorganic compounds such as expanded graphite (EG).

[0055] In this application, the content of phosphorus-containing flame retardant in the flame-retardant material can be comparable to the content of polysiloxane (or other flame retardants), with both exerting a synergistic flame-retardant effect, rather than one supplementing the other's flame-retardant performance with a small mass proportion. The phosphorus-containing flame retardant can form a good flame-retardant effect with polysiloxane, and the composite flame retardant formed by their mutual compounding can improve the anti-dripping performance of the flame-retardant material, while achieving a thin-walled V-0 flame retardant rating in a fluorine-free formulation. In some embodiments, the content of polysiloxane can also be a smaller proportion compared to the content of the phosphorus-containing flame retardant. The polysiloxane enhances and synergizes with the phosphorus-containing flame retardant at a small mass ratio.

[0056] The flame-retardant material may also include an antioxidant. The antioxidant can be used to improve the durability of the flame-retardant material and maintain its long-term performance. Exemplary antioxidants may include, but are not limited to, 2,6-di-tert-butyl-4-methylphenol, 2,2'-methylenebis(4-methyl-6-tert-butylphenol), pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], tris(2,4-di-tert-butylphenyl)phosphite, N,N'-bis(β-hydroxyethyl)-5-methylhydrazine-1,3-dicarboxamide, 2,2'-thiodiethanolbis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxyphenyl)benzene, n-octyl 3,5-di-tert-butyl-4-hydroxybenzoate, 2,2'-methylenebis(4-ethyl-6-tert-butylphenol), distearate thiodipropionate, 2-(1, 1-Dimethylethyl)-6-[3-(1,1-dimethylethyl)-2-hydroxy-5-methylphenyl]methyl-4-methylphenol, β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate n-dodecyl ester, di(2,2,6,6-tetramethyl-4-piperidinyl) sebacate, 2,2'-thionyldiethanol bis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), 1,6-hexanediol bis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), 2,4-di-tert-butyl-6-(3-tert-butyl-2-hydroxy-5-methylbenzyl)phenol, pentamethylbis(β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), 2,2'-methylenebis(6-tert-butyl-4-ethylphenol), etc., or any group thereof.

[0057] The antioxidant may be present in a mass percentage range of 0.1% to 1%, for example, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, etc. Alternatively, the antioxidant may be any value within the above range, such as 0.3%.

[0058] The flame retardant may also include a lubricant. The lubricant can improve the processing performance, surface properties, and mechanical properties of the material. Exemplary lubricants may include, but are not limited to, stearic acid, calcium stearate, zinc stearate, magnesium stearate, montmorillonite, talc, polyethylene wax, polyethylene distearate, stearamide, ethylene bis-stearamide, silicone oil, silicone powder, oxidized polyethylene wax, castor oil derivatives, lauramide, glyceryl stearate, pentaerythritol stearate, polypropylene wax, propylene distearate, beeswax, paraffin wax, etc., or any combination thereof. Similarly, the mass percentage of the lubricant may be 0.1%-1%, for example, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, etc. Alternatively, the mass percentage of the lubricant may be any value within the above range, such as 0.3%.

[0059] In some embodiments, other additives, such as release agents, heat stabilizers, smoke suppressants, annual modifiers, or additives that achieve other effects, may be used to participate in the composition of the flame retardant material.

[0060] This application also discloses a method for preparing the above-mentioned flame-retardant materials. The preparation method may include the following exemplary steps.

[0061] The first step is to place each component in a mixing device and mix them evenly according to the mass ratio of each component of the flame retardant material to obtain a mixture.

[0062] In some embodiments, after the components of the flame-retardant material are weighed, they can be placed in a mixing device for blending to obtain a homogeneous mixture. The mixing device used can be any type of device capable of mixing, such as a horizontal mixer, vertical mixer, double cone mixer, V-type mixer, trough mixer, kneader, planetary mixer, fluidized bed mixer, spiral cone mixer, belt mixer, tipping bucket mixer, airflow mixer, high-speed mixer, slurry mixer, vacuum mixer, etc. The mixing of the components can be dry mixing, melt mixing, solution mixing, or any combination thereof. In some embodiments, the mixing of the components of the flame-retardant material can be achieved under molten conditions. Thermoplastic polymers, phosphorus-containing flame retardants, polysiloxanes, antioxidants, lubricants, and other additives (if any) can be premixed in a mixing device (e.g., a twin-screw extruder, a single-screw extruder, a kneader, a planetary mixer, etc.). Subsequently, the reinforcing material is added and mixed with the premix to obtain a homogeneous mixture. A suitable, but non-limiting, example could be the use of a twin-screw extruder for component mixing. The reinforcing material, such as a glass fiber composition, is added to the mixing chamber via side feeding and mixed with the premix.

[0063] The second step involves using an extrusion device to extrude the mixture into strips, which are then transferred to a granulation device for granulation. After post-processing, the flame-retardant material is obtained.

[0064] In some embodiments, the mixture can be transferred to an extrusion apparatus for strip extrusion. Alternatively, the aforementioned mixing apparatus can simultaneously perform extrusion, so as to be further used as the extrusion apparatus in a second step. Examples include various types of extruders, including single-screw extruders, twin-screw extruders, conical twin-screw extruders, multi-screw extruders, planetary screw extruders, etc. After the components constituting the flame-retardant material are uniformly mixed in any of the above-mentioned suitable extruders, strip extrusion is then performed. The strip can be transferred to a pelletizing apparatus for pelletizing, for example, by directly cutting the strip using a hot pelletizer. Alternatively, the obtained strip can be cooled, for example, by placing it in a water tank and cooling it with flowing cooling water (e.g., 15°C-20°C). It is then transferred to a pelletizer (e.g., a cold pelletizer, rotary pelletizer, oscillating pelletizer, etc.) for strip cutting. The rotation speed of the pelletizer can be between 500-700 rpm, for example, 500 rpm, 550 rpm, 600 rpm, 650 rpm, 700 rpm, etc., or it can be adjusted according to the actual process conditions or process requirements. This is not a limitation.

[0065] The precursor particles of the flame retardant material obtained after granulation can be processed to obtain the flame retardant material. The post-processing may include one or more of the following: cooling (e.g., to stabilize particle shape and prevent agglomeration), drying (e.g., to remove surface and internal moisture), sieving (e.g., to separate particles of different sizes and ensure uniformity), dust removal (e.g., to remove fine dust and improve product purity), metal separation (e.g., to remove any metal impurities that may be mixed in), surface treatment (e.g., performance improvement), coloring (e.g., to meet specific color requirements), and metering and packaging (e.g., for easy storage and transportation).

[0066] The flame-retardant materials disclosed in this application can be used to prepare various products, such as electronic and electrical components, automotive parts, household goods, aerospace components, power facilities, medical devices, and energy storage protective components. Common thermoplastic processes such as injection molding, extrusion molding, blow molding, hot pressing, calendering, hot melt bonding, heat sealing, and 3D printing can be used to prepare the flame-retardant materials into the aforementioned products.

[0067] The present application will be further described in detail below with reference to embodiments. It should be noted that the following embodiments are for illustrative purposes only and are not intended to limit the scope of protection claimed in this application.

[0068] The reagents used in the examples were sourced from the following sources:

[0069] Example 1 - Preparation of Flame Retardant Materials

[0070] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio of 5:63.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers in the glass fiber composition is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. The specific mass ratios are shown in Table 1.

[0071] The preparation process is as follows:

[0072] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0073] Example 2 - Preparation of Flame Retardant Materials

[0074] Example 2 differs from Example 1 in that the ratio of linear homopolymer polycarbonate (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition is different.

[0075] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 3:65.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. The specific mass ratios are shown in Table 1.

[0076] The preparation process is as follows:

[0077] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0078] Example 3 - Preparation of Flame Retardant Materials

[0079] Example 3 differs from Example 1 in that the ratio of linear homopolymer polycarbonate (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition is different.

[0080] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio of 10:58.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. The specific mass ratios are shown in Table 1.

[0081] The preparation process is as follows:

[0082] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0083] Example 4 - Preparation of Flame Retardant Materials

[0084] Example 4 differs from Example 1 in that the ratio of linear homopolymer polycarbonate (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition is different.

[0085] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 23:45.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 1.

[0086] The preparation process is as follows:

[0087] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0088] Example 5 - Preparation of Flame Retardant Materials

[0089] Example 5 differs from Example 1 in that the melt indexes of linear homopolymer and branched polycarbonate in the polycarbonate composition are different.

[0090] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=36) and branched polycarbonate (MFR=3) (mass ratio 5:65.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. The specific mass ratios are shown in Table 1.

[0091] The preparation process is as follows:

[0092] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0093] Example 6 - Preparation of Flame Retardant Materials

[0094] Example 6 differs from Example 1 in that the melt indexes of linear homopolymer and branched polycarbonate in the polycarbonate composition are different.

[0095] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=12) (mass ratio 5:65.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. The specific mass ratios are shown in Table 1.

[0096] The preparation process is as follows:

[0097] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0098] Example 7 - Preparation of Flame Retardant Materials

[0099] Example 7 differs from Example 1 in that the ratio of flat glass fibers to round glass fibers in the glass fiber composition is different.

[0100] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:63.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 15:5; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 2.

[0101] The preparation process is as follows:

[0102] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0103] Example 8 - Preparation of Flame Retardant Materials

[0104] Example 8 differs from Example 1 in that the ratio of flat glass fibers to round glass fibers in the glass fiber composition is different.

[0105] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:63.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 19:1; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. The specific mass ratios are shown in Table 2.

[0106] The preparation process is as follows:

[0107] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0108] Example 9 - Preparation of Flame Retardant Materials

[0109] Example 9 differs from Example 1 in that the flatness ratio of the flat glass fibers in the glass fiber composition is different.

[0110] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio of 5:63.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers in the glass fiber composition is 1:3, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. The specific mass ratios are shown in Table 2.

[0111] The preparation process is as follows:

[0112] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0113] Example 10 - Preparation of Flame Retardant Materials

[0114] The difference between Example 10 and Example 1 is that the diameter of the circular glass fibers in the glass fiber composition is different.

[0115] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:63.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers in the glass fiber composition is 1:3, the diameter of the round glass fibers is 7 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. The specific mass ratios are shown in Table 2.

[0116] The preparation process is as follows:

[0117] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0118] Example 11 - Preparation of Flame Retardant Materials

[0119] Example 11 differs from Example 1 in that the diameter of the circular glass fibers in the glass fiber composition is different.

[0120] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:63.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers in the glass fiber composition is 1:3, the diameter of the round glass fibers is 13 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. The specific mass ratios are shown in Table 2.

[0121] The preparation process is as follows:

[0122] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0123] Example 12 - Preparation of Flame Retardant Materials

[0124] Example 12 differs from Example 1 in that the phosphorus-containing flame retardant is a mixture of phosphazene and bisphenol A bis(phenyl phosphate) in a different mass ratio. Additionally, the ratio of linear homopolymer polycarbonate (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition is different.

[0125] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:61.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and bisphenol A bis(phenyl phosphate) in a mass ratio of 1:7, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 66.4:20:8:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 3.

[0126] The preparation process is as follows:

[0127] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0128] Example 13 - Preparation of Flame Retardant Materials

[0129] Example 14 differs from Example 1 in that the mass ratio of phosphazene to resorcinol bis(diphenyl phosphate) in the phosphorus-containing flame retardant is different, as is the ratio of linear homopolymer (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition.

[0130] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:62.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 2:5, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 67.4:20:7:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 3.

[0131] The preparation process is as follows:

[0132] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0133] Example 14 - Preparation of Flame Retardant Materials

[0134] Example 14 differs from Example 1 in that the mass ratio of phosphazene to resorcinol bis(diphenyl phosphate) in the phosphorus-containing flame retardant is different, as is the ratio of linear homopolymer (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition.

[0135] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:64.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:3, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 69.4:20:4:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 3.

[0136] The preparation process is as follows:

[0137] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0138] Example 15 - Preparation of Flame Retardant Materials

[0139] Example 15 differs from Example 1 in that the mass ratio of phosphazene to resorcinol bis(diphenyl phosphate) in the phosphorus-containing flame retardant is different, as is the ratio of linear homopolymer (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition.

[0140] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:61.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 2:6, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 66.4:20:8:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 3.

[0141] The preparation process is as follows:

[0142] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0143] Example 16 - Preparation of Flame Retardant Materials

[0144] Example 16 differs from Example 1 in that the mass ratio of phosphazene to resorcinol bis(diphenyl phosphate) in the phosphorus-containing flame retardant is different, as is the ratio of linear homopolymer (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition.

[0145] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:57.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) at a mass ratio of 1:11, and the polysiloxane has an (a+b):c ratio of 0.68:1. The above components are taken in a mass ratio of 62.4:20:12:5, and the remainder is antioxidant and lubricant, with a mass percentage of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 3.

[0146] The preparation process is as follows:

[0147] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0148] Example 17 - Preparation of Flame Retardant Materials

[0149] Compared with Example 1, Example 17 differs in that the mass ratio of phosphazene to resorcinol bis(diphenyl phosphate) in the phosphorus-containing flame retardant is different, and the mass percentage of polysiloxane is also different.

[0150] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:63.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:6; the polysiloxane has an (a+b):c ratio of 0.68:1 and a mass percentage of 4%. The above components are taken in a mass ratio of 68.4:20:7:4, and the remainder is antioxidant and lubricant, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 4.

[0151] The preparation process is as follows:

[0152] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0153] Example 18 - Preparation of Flame Retardant Materials

[0154] Example 18 differs from Example 1 in the following ways: the mass percentage of polysiloxane, the ratio of linear homopolymer polycarbonate (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition, and the ratio of phosphazene compounds to phosphate ester compounds in the phosphorus-containing composition.

[0155] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio of 5:66.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) at a mass ratio of 1:10; the polysiloxane has an (a+b):c ratio of 0.68:1 and a mass percentage of 0.4%; the above components are taken in a mass ratio of 71.4:20:11:0.4; the remainder is antioxidant and lubricant, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 4.

[0156] The preparation process is as follows:

[0157] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0158] Example 19 - Preparation of Flame Retardant Materials

[0159] Example 19 differs from Example 1 in the mass percentage of polysiloxane and the ratio of linear homopolymer polycarbonate (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition.

[0160] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:66.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5; the polysiloxane has an (a+b):c ratio of 0.68:1 and a mass percentage of 2%; the above components are taken in a mass ratio of 71.4:20:6:2; the remainder is antioxidant and lubricant, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 4.

[0161] The preparation process is as follows:

[0162] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0163] Example 20 - Preparation of Flame Retardant Materials

[0164] Example 20 differs from Example 1 in the mass percentage of polysiloxane and the ratio of linear homopolymer polycarbonate (MFR=2) to branched polycarbonate (MFR=3) in the polycarbonate composition.

[0165] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:48.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5; the polysiloxane has an (a+b):c ratio of 0.68:1 and accounts for 20% of the mass; the above components are taken in a mass ratio of 53.4:20:6:20, and the remainder is antioxidant and lubricant, accounting for 0.3% and 0.3% of the mass, respectively. Specific mass ratios are shown in Table 4.

[0166] The preparation process is as follows:

[0167] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0168] Example 21 - Preparation of Flame Retardant Materials

[0169] Example 21 differs from Example 1 in that the polysiloxane structure is different.

[0170] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:63.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5; the polysiloxane has an (a+b):c ratio of 0.4:1 and a mass percentage of 5%; the above components are taken in a mass ratio of 68.4:20:6:5; the remainder is antioxidant and lubricant, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 4.

[0171] The preparation process is as follows:

[0172] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0173] Example 22 - Preparation of Flame Retardant Materials

[0174] Example 22 differs from Example 1 in that the polysiloxane structure is different.

[0175] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:63.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fiber is 1:4, the diameter of the round glass fiber is 10 micrometers, and the mass ratio of the flat glass fiber to the round glass fiber is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:5; the polysiloxane has an (a+b):c ratio of 1:1 and a mass percentage of 5%; the above components are taken in a mass ratio of 68.4:20:6:5; the remainder is antioxidant and lubricant, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 4.

[0176] The preparation process is as follows:

[0177] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0178] Example 23 - Preparation of Flame Retardant Materials

[0179] Example 23 differs from Example 1 in that the reinforcing material is carbon fiber instead of a glass fiber composition.

[0180] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:63.4); the reinforcing material is carbon fiber, accounting for 20% by mass; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate), with a mass ratio of 1:5; the polysiloxane has an (a+b):c ratio of 1:1, accounting for 5% by mass; the above components are taken in a mass ratio of 68.4:20:6:5; and the remainder is antioxidant and lubricant, accounting for 0.3% and 0.3% by mass, respectively. Specific mass ratios are shown in Table 5.

[0181] The preparation process is as follows:

[0182] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, carbon fiber is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator, and finally packaged to obtain the final product.

[0183] Example 24 - Preparation of Flame Retardant Materials

[0184] Example 24 differs from Example 1 in that the phosphorus-containing flame retardant is aluminum diethylphosphite, which forms a composite flame retardant with MPP instead of silicone resin.

[0185] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio of 5:61.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is diethylaluminum hypophosphite, accounting for 10% by mass, and MPP accounts for 3% by mass. The above components are taken in a mass ratio of 66.4:20:10:3, and the remainder is antioxidant and lubricant, accounting for 0.3% and 0.3% by mass, respectively. The specific mass ratios are shown in Table 6.

[0186] The preparation process is as follows:

[0187] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, MPP, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0188] Example 25 - Preparation of Flame Retardant Materials

[0189] Example 25 differs from Example 1 in that the phosphorus-containing flame retardant and MPP, rather than polysiloxane, constitute a composite flame retardant.

[0190] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio of 5:62.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:8, and the MPP mass percentage is 3%. The above components are taken in a mass ratio of 67.4:20:9:3, and the remainder is antioxidant and lubricant, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 6.

[0191] The preparation process is as follows:

[0192] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, MPP, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0193] Example 26 - Preparation of Flame Retardant Materials

[0194] Example 26 differs from Example 1 in that the phosphorus-containing flame retardant is diethylaluminum hypophosphite.

[0195] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:59.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of the flat glass fibers to the round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is diethylaluminum hypophosphite, accounting for 10% by mass, and the polysiloxane has an (a+b):c ratio of 0.68:1, accounting for 5% by mass. The above components are taken in a mass ratio of 64.4:20:10:5, and the remainder is antioxidant and lubricant, accounting for 0.3% and 0.3% by mass, respectively. The specific mass ratios are shown in Table 6.

[0196] The preparation process is as follows:

[0197] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0198] Example 27 - Preparation of Flame Retardant Materials

[0199] Example 27 differs from Example 1 in that it uses flat glass fiber alone, and the phosphorus-containing flame retardant and MPP instead of silicone resin form a composite flame retardant.

[0200] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:62.4); the reinforcing material is flat glass fiber with a flatness ratio of 1:4 and a mass percentage of 20%; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) with a mass ratio of 1:8, and the MPP mass percentage is 3%. The above components are taken in a mass ratio of 67.4:20:9:3, and the remainder is antioxidant and lubricant, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 6.

[0201] The preparation process is as follows:

[0202] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, MPP, and other additives are added to a twin-screw extruder for compounding. During compounding, flat glass fibers are added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator, and finally packaged to obtain the final product.

[0203] Example 28 - Preparation of Flame Retardant Materials

[0204] Example 28 differs from Example 1 in that the phosphorus-containing flame retardant and MPP, rather than polysiloxane, constitute a composite flame retardant.

[0205] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio of 5:62.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) in a mass ratio of 1:8, and the MPP mass percentage is 3%. The above components are taken in a mass ratio of 67.4:20:9:3, and the remainder is antioxidant and lubricant, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 6.

[0206] The preparation process is as follows:

[0207] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, MPP, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0208] Example 29 - Preparation of Flame Retardant Materials

[0209] Example 29 differs from Example 1 in that it uses flat glass fiber alone.

[0210] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:63.4); the reinforcing material is flat glass fiber with a flatness ratio of 1:4 and a mass percentage of 20%; the phosphorus-containing flame retardant in the composite flame retardant is a mixture of phosphazene and resorcinol bis(diphenyl phosphate) with a mass ratio of 1:5; the polysiloxane has an (a+b):c ratio of 0.68:1 and a mass percentage of 5%. The above components are taken in a mass ratio of 68.4:20:6:5, and the remainder is antioxidant and lubricant, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 6.

[0211] The preparation process is as follows:

[0212] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, flat glass fibers are added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator, and finally packaged to obtain the final product.

[0213] Example 30 - Preparation of Flame Retardant Materials

[0214] Example 30 differs from Example 1 in that it uses flat glass fiber alone and the phosphorus-containing flame retardant is diethyl aluminum hypophosphite.

[0215] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio 5:61.4); the reinforcing material is flat glass fiber with a flatness ratio of 1:4 and a mass percentage of 20%; the phosphorus-containing flame retardant in the composite flame retardant is diethylaluminum hypophosphite, with a mass percentage of 8%; the polysiloxane has an (a+b):c ratio of 0.68:1 and a mass percentage of 5%. The above components are produced in a mass ratio of 66.4:20:8:5, with the remainder being antioxidants and lubricants, with mass percentages of 0.3% and 0.3%, respectively. Specific mass ratios are shown in Table 6.

[0216] The preparation process is as follows:

[0217] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, flat glass fibers are added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator, and finally packaged to obtain the final product.

[0218] Example 31 - Preparation of Flame Retardant Materials

[0219] Example 31 differs from Example 1 in that it uses flat glass fiber alone and the phosphorus-containing flame retardant is diethyl aluminum hypophosphite.

[0220] In this embodiment, the thermoplastic polymer is a polycarbonate composition of linear homopolymer (MFR=2) and branched polycarbonate (MFR=3) (mass ratio of 5:61.4); the reinforcing material is a glass fiber composition, wherein the flatness ratio of the flat glass fibers is 1:4, the diameter of the round glass fibers is 10 micrometers, and the mass ratio of flat glass fibers to round glass fibers is 17:3; the phosphorus-containing flame retardant in the composite flame retardant is diethylaluminum hypophosphite, accounting for 8% by mass; the polysiloxane has an (a+b):c ratio of 0.68:1, accounting for 5% by mass; the above components are produced in a mass ratio of 66.4:20:8:5; and the remainder is antioxidant and lubricant, accounting for 0.3% and 0.3% by mass, respectively. Specific mass ratios are shown in Table 6.

[0221] The preparation process is as follows:

[0222] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0223] Comparative Example 1 - Preparation of Flame Retardant Materials

[0224] The difference between Comparative Example 1 and Example 1 is that the thermoplastic polymer is a linear homopolymer carbonate (MFR=2).

[0225] In Comparative Example 1, linear homopolymer carbonate (MFR=2) (68.4% by mass) was used; the linear homopolymer carbonate, glass fiber composition, phosphorus-containing flame retardant, polysiloxane, antioxidant, and lubricant were prepared in a mass ratio of 68.4:20:6:5:0.3:0.3. The specific mass ratios are shown in Table 1.

[0226] The preparation process is as follows:

[0227] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0228] Comparative Example 2 - Preparation of Flame Retardant Materials

[0229] The difference between Comparative Example 2 and Example 1 lies in the different mass ratio of linear homopolymer polycarbonate to branched polycarbonate in the polycarbonate composition.

[0230] In Comparative Example 2, the mass ratio of linear homopolymer polycarbonate (MFR=2) to branched polycarbonate (MFR=3) was 25:43.4. The polycarbonate composition, glass fiber composition, phosphorus-containing flame retardant, polysiloxane, antioxidant, and lubricant were prepared in a mass ratio of 68.4:20:6:5:0.3:0.3. Specific mass ratios are shown in Table 1.

[0231] The preparation process is as follows:

[0232] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0233] Comparative Example 3 - Preparation of Flame Retardant Materials

[0234] Comparative Example 3 differs from Example 1 in that it uses only flat glass fiber.

[0235] In Comparative Example 3, the polycarbonate composition, flat glass fiber, phosphorus-containing flame retardant, polysiloxane, antioxidant, and lubricant were prepared in a mass ratio of 68.4:20:6:5:0.3:0.3. The specific mass ratios are shown in Table 2.

[0236] The preparation process is as follows:

[0237] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0238] Comparative Example 4 - Preparation of Flame Retardant Materials

[0239] Comparative Example 4 differs from Example 1 in that it uses only circular glass fibers.

[0240] In Comparative Example 4, the polycarbonate composition, round glass fiber, phosphorus-containing flame retardant, polysiloxane, antioxidant, and lubricant were prepared in a mass ratio of 68.4:20:6:5:0.3:0.3. The specific mass ratios are shown in Table 2.

[0241] The preparation process is as follows:

[0242] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0243] Comparative Example 5 - Preparation of Flame Retardant Materials

[0244] The difference between Comparative Example 5 and Example 1 is that the mass ratio of flat glass fiber to round glass fiber in the glass fiber composition is different, which is 1:1.

[0245] In Comparative Example 5, the polycarbonate composition, glass fiber composition, phosphorus-containing flame retardant, polysiloxane, antioxidant, and lubricant were prepared in a mass ratio of 68.4:20:6:5:0.3:0.3. The specific mass ratios are shown in Table 2.

[0246] The preparation process is as follows:

[0247] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0248] Comparative Example 6 - Preparation of Flame Retardant Materials

[0249] The difference between Comparative Example 6 and Example 1 is that the phosphorus-containing flame retardant is resorcinol bis(diphenyl phosphate).

[0250] In Comparative Example 6, the polycarbonate composition, glass fiber composition, phosphorus-containing flame retardant (resorcinol bis(diphenyl phosphate)), polysiloxane, antioxidant, and lubricant were prepared in a mass ratio of 68.4:20:6:5:0.3:0.3. The specific mass ratios are shown in Table 2.

[0251] The preparation process is as follows:

[0252] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, polysiloxane, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0253] Comparative Example 7 - Preparation of Flame Retardant Materials

[0254] Comparative Example 7 differs from Example 1 in that it uses a phosphorus-containing flame retardant alone instead of polysiloxane, and the mass ratio of phosphazene to resorcinol bis(diphenyl phosphate) in the phosphorus-containing flame retardant is different.

[0255] In Comparative Example 7, the polycarbonate composition, glass fiber composition, phosphorus-containing flame retardant, antioxidant, and lubricant were prepared in a mass ratio of 68.4:20:9:0.3:0.3. The specific mass ratios are shown in Table 4.

[0256] The preparation process is as follows:

[0257] All the above raw materials are mixed evenly using a mixer. First, polycarbonate, phosphorus-containing flame retardant, and other additives are added to a twin-screw extruder for compounding. During compounding, the glass fiber composition is added via side feeding. After uniform mixing, the mixture is extruded into strips, which are then cooled in a water bath at a temperature of 15-20°C. After cooling, the strips are fed into a pelletizer for pelletizing at a speed of 500-700 rpm. The pellets are then dried using an elevator and packaged to obtain the final product.

[0258] Flame retardancy rating test

[0259] Flame retardancy rating tests were conducted on products prepared from the flame retardant materials obtained in Examples 1-31 and Comparative Examples 1-7. The flame retardant test strips were treated under two conditions: Condition 1: 23°C, 50% RH for 48 hours; Condition 2: 70°C oven for 168 hours. The vertical burning flame retardancy rating was tested according to UL94 standards for both conditions, and the lower rating was taken as the final flame retardancy rating. The test results are summarized in Tables 1-6.

[0260] Tensile strength and elongation at break test

[0261] Products made from the flame-retardant materials obtained in Examples 1-31 and Comparative Examples 1-7 were subjected to tensile strength and elongation at break tests: the tensile test was conducted according to ISO 527 standard, the tensile speed was 5 mm / min, and the average value of 5 samples was taken. The test results are summarized in Tables 1-6.

[0262] Notched impact test of simply supported beam

[0263] Products made from flame-retardant materials obtained in Examples 1-31 and Comparative Examples 1-7 were subjected to notched impact tests on simply supported beams. The impact test strips were notched according to ISO 179 before testing. The test temperature was 23°C, and 10 strips were tested, with the average value taken. The test results are summarized in Tables 1-6.

[0264] Table 1. Composition and test results of flame-retardant materials

[0265] Table 2 Composition and test results of flame-retardant materials

[0266] Table 3 Composition and test results of flame-retardant materials

[0267] Table 4 Composition and test results of flame-retardant materials

[0268] Table 5 Composition and test results of flame-retardant materials

[0269] Table 6 Composition and Test Results of Flame Retardant Materials

[0270] As can be seen from Tables 1 to 6 above, the flame-retardant material provided in this application embodiment can achieve a higher flame-retardant rating (achieving a flame-retardant rating of 0.6mm V-0) compared to the comparative example, and the tensile strength and elongation at break did not degrade due to changes in composition. Furthermore, the notched impact test results of a simply supported beam show that the material's toughness did not decrease.

[0271] The basic concepts have been described herein. It is obvious that the detailed disclosure above is merely illustrative and does not constitute a limitation of this application. Although not explicitly stated herein, various modifications, improvements, and corrections may be made to this application by those skilled in the art. Such modifications, improvements, and corrections are suggested in this application and therefore remain within the spirit and scope of the exemplary embodiments of this application.

[0272] Meanwhile, this application uses specific terms to describe its embodiments. For example, "an embodiment," "one embodiment," "some embodiments," and / or "some implementations" refer to a particular feature, structure, or characteristic related to at least one embodiment of this application. Therefore, it should be emphasized and noted that "an embodiment," "one embodiment," or "an alternative embodiment" mentioned twice or more in different locations in this application do not necessarily refer to the same embodiment. Furthermore, certain features, structures, or characteristics in one or more embodiments of this application can be appropriately combined.

[0273] Similarly, it should be noted that, in order to simplify the description of this application and thus aid in the understanding of one or more embodiments of the invention, the foregoing description of the embodiments of this application sometimes combines multiple features into one embodiment or its description. However, this disclosure method does not imply that the subject matter of this application requires more features than those mentioned in the claims. In fact, the embodiments have fewer features than all the features of the single embodiments disclosed above.

[0274] Finally, it should be understood that the embodiments described in this application are merely illustrative of the principles of the embodiments of this application. Other modifications may also fall within the scope of this application. Therefore, alternative configurations of the embodiments of this application are considered as examples and not limitations, and are regarded as consistent with the teachings of this application. Accordingly, the embodiments of this application are not limited to the embodiments explicitly described and illustrated in this application.

Claims

1. A flame-retardant material, characterized in that, The flame-retardant material includes: Thermoplastic polymers; Reinforcing materials; and Composite flame retardants, including phosphorus-containing flame retardants and polysiloxanes; The mass ratio of the thermoplastic polymer, the reinforcing material, the phosphorus-containing flame retardant, and the polysiloxane is (30-80):(10-50):(4-12):(0.4-20). The structural formula of the polysiloxane is: [(R1)2(R2)SiO 1 / 2 ] a ·[(R3)3SiO 1 / 2 ] b ·[SiO 4 / 2 ] c R1, R2 and R3 may be the same or different, and each independently comprises an alkyl or substituted alkyl group containing no more than 30 carbon atoms, an alkenyl or substituted alkenyl group containing no more than 30 carbon atoms, an alkynyl or substituted alkynyl group containing no more than 30 carbon atoms, and / or an aryl or substituted aryl group containing no more than 30 carbon atoms; (a+b):c = (0.4-1):

1.

2. The flame-retardant material according to claim 1, characterized in that, The thermoplastic polymer comprises a mixture of linear homopolymer and branched polycarbonate; the mass ratio of the linear homopolymer to the branched polycarbonate is (0.05-0.5):1; the melt index of the linear homopolymer is 1-40 g / 10 min, and the melt index of the branched polycarbonate is 2-15 g / 10 min.

3. The flame-retardant material according to claim 1, characterized in that, The thermoplastic polymer contains at least 30% recycled material.

4. The flame-retardant material according to claim 1, characterized in that, The reinforcing material includes one or more of glass fiber composition, carbon fiber, and metal fiber; the carbon fiber contains at least 30% recycled material.

5. The flame-retardant material according to claim 4, characterized in that, The glass fiber composition comprises flat glass fiber and round glass fiber, wherein the mass ratio of the flat glass fiber to the round glass fiber is 1:(0.05-0.3); the flatness ratio of the flat glass fiber is 1:3-1:4, and the diameter of the round glass fiber is 7-13 micrometers.

6. The flame-retardant material according to claim 1, characterized in that, The phosphorus-containing flame retardant is selected from one or more phosphazene compounds and / or one or more phosphate ester compounds; wherein the mass ratio of the phosphazene compound to the phosphate ester compound is 1:(3-11).

7. The flame-retardant material according to claim 6, characterized in that, The phosphazene compound is hexaphenoxycyclotriphosphazene, and the phosphate ester compound is bisphenol A bis(diphenyl phosphate) and / or resorcinol bis(diphenyl phosphate).

8. The flame-retardant material according to claim 1, characterized in that, The structural formula of the polysiloxane is: [(CH3)2(CH2=CH)SiO 1 / 2 ] a ·[(CH3)3SiO 1 / 2 ] b ·[SiO 4 / 2 ] c .

9. The flame-retardant material according to claim 1, characterized in that, The flame retardant material further includes an antioxidant, which includes one or more of antioxidant 168, antioxidant 1010, and antioxidant 1098.

10. The flame-retardant material according to claim 1, characterized in that, The flame-retardant material further includes a lubricant, which includes one or more of calcium stearate, stearic acid, ethylene bis-stearamide, pentaerythritol stearate, silicone powder, and polyethylene wax.

11. A method for preparing a flame-retardant material as described in any one of claims 1-10, characterized in that, The preparation method includes: Based on the mass ratio of each component of the flame retardant material, each component is placed in a mixing device and mixed evenly to obtain a mixture; The mixture is extruded into strips using an extrusion device and transferred to a granulation device for granulation. After post-processing, the flame-retardant material is obtained.

12. An article of manufacture made of a flame-retardant material as described in any one of claims 1-11.

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