Alkyl Phosphite and Epoxy Stabilizers for Brominated Polymers

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Solution Overview

Problem

Brominated polymeric flame retardants used in polymer systems face issues with thermal instability, leading to bromine liberation during melt processing, which causes loss of flame retardation performance, polymer degradation, and the formation of gels that affect foam structure and properties, particularly in thermoplastic foam extrusion processes.

Innovation Solution

Incorporating alkyl phosphite and epoxy compounds during melt processing of aliphatic bromine-containing polymers to enhance thermal stability and prevent gel formation, allowing for the recycling of scrap materials without significant adverse effects on foam properties or processing operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aliphatic bromine-containing polymers are used as flame retardants, then flame retardation performance is improved, but thermal stability deteriorates leading to bromine liberation during melt processing

Engineering Contradiction:

Improveflame retardation performanceVSAvoidthermal stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

Alkyl phosphite compounds and epoxy compounds are introduced as intermediary substances that mediate between the thermally unstable brominated polymer and the processing environment. These stabilizers preferentially react with liberated bromine or hydrogen bromide, preventing direct degradation of the polymer chains and maintaining both flame retardation performance and thermal stability during processing

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If bromine is liberated during melt processing, then processing becomes simpler, but harmful effects increase including polymer degradation and gel formation

Engineering Contradiction:

Improvemelt processingVSAvoidpolymer degradation and gel formation

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The invention converts the harmful effect of bromine liberation into a beneficial outcome by using alkyl phosphite and epoxy stabilizers that transform free bromine and HBr into stable compounds. The stabilizers sacrifice themselves to capture the harmful bromine species, converting a degradation pathway into a protective mechanism that prevents gel formation while allowing smooth melt processing

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If high molecular weight brominated polymers are used, then flame retardation efficiency is improved, but gel formation increases during recycling

Engineering Contradiction:

Improveflame retardation efficiencyVSAvoidresistance to gel formation

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

Alkyl phosphite and epoxy stabilizers are incorporated beforehand into the brominated polymer system to provide protective cushioning against thermal degradation. This pre-established protection system is particularly important for high molecular weight polymers that are more susceptible to gel formation during repeated processing and recycling operations

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Productivity

If scrap materials are recycled to reduce costs, then productivity is improved, but gel accumulation increases affecting product quality

Engineering Contradiction:

Improvescrap recyclingVSAvoidproduct quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention enables effective recovery of scrap materials by using stabilizers that prevent irreversible gel formation during recycling. The alkyl phosphite and epoxy compounds maintain polymer chain integrity through multiple processing cycles, allowing scrap to be discarded and recovered without accumulating gels that would compromise product quality

Inventive Principle:

Principle #34Discarding and recovering

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 use of alkyl phosphite and epoxy compounds significantly reduces gel formation and improves thermal stability, enabling the recycling of scrap materials and maintaining the quality of the final product, while minimizing costs and adverse effects on processing equipment and foam properties.

Implementation Method 1

Incorporating alkyl phosphite and epoxy compounds during melt processing of aliphatic bromine-containing polymers to enhance thermal stability and prevent gel formation

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

The use of alkyl phosphite and epoxy compounds significantly reduces gel formation and improves thermal stability, enabling the recycling of scrap materials

Methodology Applied

Scientific EffectThermal stability enhancement: Heat Treatment

Data Source

PatentUS9663649B2Stabilizers for polymers containing aliphatically-bound bromine

Publication Date: 2017.05.30 DDP SPECIALTY ELECTRONICS MATERIALS US LLC

AI summary

Aliphatic bromine-containing polymers are stabilized using a mixture of an alkyl phosphite and an epoxy compound. This stabilizer package is very effective at preventing cross-linking reactions from occurring when the aliphatic bromine-containing polymer is subjected to high temperatures as are seen in melt processing operations. The stabilized aliphatic bromine-containing polymer is useful as a flame retardant for other polymers, notably polystyrene foam.