Cyclic Phosphonate Ester Flame Retardant Polyamide 3D Printing
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Solution Overview
Problem
Current flame-retardant polyamide and copolyamide powders for powder bed fusion technologies face challenges in achieving cost-effective fire resistance, environmental sustainability, preserving mechanical properties, and ensuring dimensional stability, particularly due to the limitations of halogenated compounds and additives like ammonium polyphosphate which cause water absorption and coalescence issues.
Innovation Solution
Incorporating a cyclic phosphonate ester type flame retardant agent into polyamide and copolyamide powders for 3D printing, which allows for the production of well-sintered, flame-retardant parts with superior mechanical properties and reduced coalescence problems, while being environmentally friendly and cost-effective.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogenated flame retardant compounds are used, then fire resistance is achieved, but environmental harm and toxicity increase
Solution Approach 1:
The patent changes the chemical composition parameters by replacing halogenated compounds with non-halogenated alternatives, specifically using phosphorus-based flame retardants. This substitution maintains the fire resistance function while eliminating the harmful environmental effects associated with halogenated compounds.
Solution Approach 2:
The patent employs readily available phosphorus-based flame retardant additives that can be easily incorporated into polyamide powders. These alternatives provide effective fire protection without the long-term environmental persistence and toxicity of halogenated compounds, offering a sustainable solution.
2Reliability
If ammonium polyphosphate is used as flame retardant, then fire resistance is achieved, but water uptake increases and dimensional stability deteriorates
Solution Approach 1:
The patent changes the chemical composition by substituting ammonium polyphosphate with phosphorus-based flame retardants that have different hygroscopic properties. This parameter change reduces water uptake while maintaining fire resistance, thereby preserving dimensional stability of the 3D printed parts.
3Reliability
If flame retardant additives are incorporated into polyamide powder, then fire resistance is improved, but mechanical properties and sintering quality deteriorate
Solution Approach 1:
The patent applies flame retardant additives at optimized local concentrations within the polyamide powder matrix. By carefully controlling the distribution and amount of phosphorus-based flame retardant, the invention maintains mechanical properties and sintering quality while achieving fire resistance.
Solution Approach 2:
The patent creates a composite material system combining polyamide with phosphorus-based flame retardants. This composite approach allows the flame retardant to be integrated at the molecular level, maintaining the mechanical integrity and sintering behavior of the base polyamide while providing fire protection.
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 cyclic phosphonate ester as a flame retardant agent in polyamide and copolyamide powders for 3D printing achieves fireproofing equivalent to or better than existing methods, maintains mechanical properties, and ensures good recyclability, making it suitable for producing high-quality, flame-retardant parts without the drawbacks of halogenated additives.
Implementation Method 1
the addition to a powder for 3D printing of a flame retardant agent of the cyclic phosphonate ester type allowed the production of good quality parts in 3D printing while giving them fireproofing equivalent to or superior to that obtained using the state of the art
Implementation Method 2
in particular a 3D printing process, more particularly by laser or infrared sintering
Implementation Method 3
in particular a 3D printing process, more particularly by laser or infrared sintering
Implementation Method 4
the selective fusion of certain areas of a powder bed
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing flame retardant parts by means of powder bed fusion, wherein the powder comprises at least one polyamide and at least one flame retardant agent in the form of a cyclic phosphonate ester.