Deoxybenzoin Polyester Flame Retardant Composition

Solution Overview

Problem

Current thermoplastic polymer molding compositions require high loadings of flame retardant additives, which negatively impact mechanical properties, and lack compatibility with other polymers in melt extrusion processes, while also not effectively reducing the amount of halogen-containing additives without compromising flame retardant properties.

Innovation Solution

A flame retardant thermoplastic polymer molding composition comprising thermoplastic polyester with 1,2-bis[4-(2-hydroxyethoxy)phenyl]ethanone units, combined with phosphorus-containing and halogen-containing flame retardant additives, and synergists, allowing for reduced amounts of these additives while maintaining flame retardant effectiveness, and processed through melt polymerization for improved compatibility and mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high loadings of flame retardant additives are used to achieve flame retardant effectiveness, then flame retardant properties are improved, but mechanical properties of the molding material deteriorate

Engineering Contradiction:

Improveflame retardant effectivenessVSAvoidmechanical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent introduces a compatibilizer as an intermediary substance that mediates between the flame retardant additives and the polyester matrix. This compatibilizer improves the interfacial adhesion and distribution of additives, allowing effective flame retardancy at lower additive loadings thereby preserving mechanical properties

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent optimizes the concentration parameters of flame retardant additives and synergists within specific ranges (0.1-50 wt% and 0-25 wt% respectively) to achieve the minimum effective dosage. This parameter optimization ensures flame retardant effectiveness while minimizing the negative impact on mechanical properties

Inventive Principle:

Principle #35Parameter changes

2Reliability

If high loadings of flame retardant additives are used to achieve flame retardant effectiveness, then flame retardant properties are improved, but the amount of halogen-containing additives cannot be reduced without compromising flame retardant properties

Engineering Contradiction:

Improveflame retardant effectivenessVSAvoidamount of halogen-containing additives

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent converts the traditionally harmful halogen-containing additives into a beneficial system by combining them with phosphorus-containing additives and synergists. This combination creates a synergistic effect where the halogen additives can be used at much lower levels (0.1-50 wt%) while still achieving effective flame retardancy through the cooperative action of multiple additives

Inventive Principle:

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

Solution Approach 2:

The patent creates a composite flame retardant system comprising multiple types of additives (phosphorus-containing, halogen-containing, and synergists) that work together. This composite approach allows the halogen-containing additives to be used in reduced amounts while maintaining or improving flame retardant effectiveness through the combined action of all components

Inventive Principle:

Principle #40Composite materials

3Reliability

If conventional flame retardant compositions are used, then flame retardant properties are achieved, but compatibility with other thermoplastic polymers in melt extrusion processes is poor

Engineering Contradiction:

Improveflame retardant propertiesVSAvoidcompatibility with other thermoplastic polymers

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent introduces a compatibilizer as an intermediary substance that mediates between the flame retardant additives and the polyester matrix. This compatibilizer improves the interfacial adhesion and distribution of additives, allowing effective flame retardancy at lower additive loadings thereby preserving mechanical properties

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent optimizes the concentration parameters of flame retardant additives and synergists within specific ranges (0.1-50 wt% and 0-25 wt% respectively) to achieve the minimum effective dosage. This parameter optimization ensures flame retardant effectiveness while minimizing the negative impact on mechanical properties

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10407539B2Deoxybenzoin containing flame retardant polymer compositions

Publication Date: 2019.09.10 BASF SE

AI summary

The present invention relates to specific deoxybenzoin containing flame retardant polyesters and flame retardant thermoplastic polymer molding compositions comprising deoxybenzoin containing flame retardant polyesters as well as their preparation and use for producing moldings, fibers or foils.