Air Spring Bellows Rubber Composition for Halogen-Free Fire Protection
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Solution Overview
Problem
Articles with elastomeric mixtures used for vehicle suspension and vibration damping fail to meet stringent fire protection requirements due to high heat release rates and toxic smoke production, while traditional fire-retardant additives compromise physical properties.
Innovation Solution
A multi-layer article with a rubber mixture layer containing hydrotalcite and sepiolite, potentially combined with chlorosulfonated polyethylene, providing improved flame retardancy without halogen-containing additives, maintaining physical properties and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional elastomeric mixtures (NR/IR or CR) are used for vehicle suspension and vibration damping, then excellent elastic properties and weather resistance are achieved, but fire protection behavior deteriorates with high heat release rates and toxic smoke production
Solution Approach 1:
The patent changes the chemical composition parameters of the rubber mixture by incorporating specific amounts of halogen-free flame retardants (at least 20 phr) along with conventional fillers and processing aids. This parameter modification enables the rubber mixture to achieve compliance with EN 45545 fire protection standards while maintaining its functional properties for suspension and vibration damping applications.
Solution Approach 2:
The patent creates a composite rubber mixture by combining halogen-free flame retardant substances with conventional rubber compounds used in vehicle suspension. This composite approach integrates fire protection functionality into the existing elastomeric material system, achieving both safety compliance and mechanical performance without requiring complete material replacement.
2Reliability
If halogen-containing flame retardants are used to improve fire protection behavior, then flame retardancy is enhanced, but environmental compatibility and health safety deteriorate due to toxic combustion products
Solution Approach 1:
The patent converts the previously harmful halogen-containing flame retardants into beneficial halogen-free alternatives. By selecting flame retardant substances that do not contain halogens, the invention eliminates the production of toxic hydrogen halide gases during combustion, while still achieving effective flame retardancy and smoke suppression suitable for railway vehicle applications.
Solution Approach 2:
The patent modifies the chemical composition by specifying the use of halogen-free flame retardants and defining their minimum content (at least 20 phr). This parameter change ensures that the rubber mixture achieves adequate flame retardancy according to EN 45545 standards without producing toxic combustion products, thereby resolving the contradiction between flame safety and environmental compatibility.
3Reliability
If fire-retardant substances are directly mixed into rubber mixtures to improve fire behavior, then flame retardancy is improved, but physical properties such as suspension and vibration performance deteriorate significantly
Solution Approach 1:
The patent optimizes the formulation parameters by specifying precise ranges for flame retardant content (at least 20 phr) while maintaining appropriate levels of reinforcing fillers, processing aids, and crosslinking agents. This balanced parameter selection ensures that fire protection requirements are met without compromising the mechanical strength, elasticity, and dynamic properties necessary for suspension and vibration damping functions.
Solution Approach 2:
The patent develops a composite rubber mixture that integrates halogen-free flame retardants with conventional rubber compounds and additives in optimized proportions. This composite formulation achieves synergistic effects where the flame retardant substances provide fire protection while the accompanying ingredients maintain or restore the physical properties required for mechanical performance in vehicle suspension applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The article achieves enhanced fire protection meeting EN45545 standards with improved flame retardancy and minimal impact on physical properties, maintaining suspension and vibration performance.
Implementation Method 1
at least one layer D of the base body is formed from a rubber mixture which is free of halogen-containing flame retardants and contains hydrotalcite and sepiolite
Implementation Method 2
Hydrotalcite is often referred to as hydrotalcite, formerly also as völknerite. It has the chemical composition Mg 6 Al 2 [(OH) 16 |CO 3 ]·4H 2 O
Implementation Method 3
Hydrotalcite has the ability to bind acids through the gradual release of aluminum hydroxide
Implementation Method 4
base body with elastic properties
Implementation Method 5
Items with outstanding elastic properties, such as metal-rubber elements or vibration dampers
Data Source
Figure 1
Figure 2~2a
AI summary
The invention relates to an article comprising a single or multi-layered main body having elastic properties, particularly an air spring bellows, a metal-rubber element or a vibration damper. The base body of the article comprises or contains, to improve the fire-retardant properties, at least one layer D which is made from a rubber mixture which is free of halogen-containing flame retardants and which contains hydrotalcite and sepiolite.