DOPO-Based Flame-Retardant Polymer for Thermoplastics
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Solution Overview
Problem
Current flame-retardant polymers for thermoplastic materials face challenges such as limited flexibility in composition, adverse impact on physical properties, incompatibility with certain substrates, and environmental concerns, particularly during melt-spinning processes, where halogen- and antimony-based retardants can cause nozzle damage and inhomogeneous distribution.
Innovation Solution
A polymer is developed through polycondensation of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) derivatives with unsaturated di- or multivalent carboxylic acids and secondary diamines, enhancing flame-retardant properties while maintaining compatibility and solubility, allowing for homogeneous distribution and reduced amounts of flame-retardant polymer usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen- or antimony-containing flame retardants are used, then flame-retardant properties are improved, but damage to spinning nozzle and environmental harm occur
Solution Approach 1:
The patent replaces harmful halogen- and antimony-containing flame retardants with environmentally benign phosphorus-containing compounds. The DOPO derivative-based flame retardant achieves effective flame protection without the toxic side effects, converting a harmful chemical approach into a beneficial one by eliminating hazardous substances while maintaining fire safety performance.
Solution Approach 2:
The patent changes the chemical composition parameters by using phosphorus-containing compounds with specific structural features (DOPO derivatives) instead of traditional halogenated compounds. This parameter change in chemical composition eliminates the harmful effects while preserving the flame-retardant function, and further optimizes solubility and distribution characteristics.
2Object-affected harmful factors
If melamine polyphosphate, melamine cyanurate or aluminum phosphinates are used, then environmental harm is reduced, but solubility in polyamides or polyesters is insufficient leading to inhomogeneous distribution
Solution Approach 1:
The patent modifies the chemical structure parameters of phosphorus-containing flame retardants by using DOPO derivatives with specific molecular architectures. These structural modifications dramatically improve solubility in polyamide and polyester matrices, enabling homogeneous distribution at the molecular level and preventing the aggregation and nozzle clogging problems associated with conventional phosphorus flame retardants.
Solution Approach 2:
The patent creates a composite system where the phosphorus-containing compound is chemically integrated into the polymer matrix through compatible molecular structures. The DOPO derivative acts as a molecular-level composite that combines the flame-retardant function with excellent compatibility and solubility in the base polymer, achieving uniform distribution without requiring physical blending of incompatible substances.
3Reliability
If copolymerization of polyamides and flame-retardant monomers is performed, then flame-retardant properties are improved, but physical properties such as melt viscosity are adversely impacted
Solution Approach 1:
The patent extracts the flame-retardant function from the polymer backbone structure and implements it as a separate additive component based on DOPO derivatives. This separation allows the base polymer to maintain its original excellent physical properties and processability, while the flame-retardant additive provides fire protection without disrupting the polymer's inherent melt behavior and mechanical characteristics.
Solution Approach 2:
The patent uses DOPO derivative compounds as intermediary substances that bridge the gap between flame-retardant functionality and polymer compatibility. These intermediary compounds act as molecular mediators that provide fire protection while maintaining excellent solubility and compatibility with the base polymer, avoiding the adverse effects of direct copolymerization on melt viscosity and physical properties.
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 polymer exhibits improved flame-retardant effectiveness with high phosphorous content, maintaining physical properties and ensuring reliable processing in extrusion and spinning processes, achieving enhanced flame-retardancy with reduced material usage and minimal environmental impact.
Implementation Method 1
A polymer, obtainable by polycondensation of a) at least one phosphorous-containing monomer selected from adducts of a1) 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) and/or nuclear substituted DOPO derivatives, with a2) at least one unsaturated di- or multivalent carboxylic acid or ester or anhydride thereof; b) at least one secondary diamine
Data Source
AI summary
The invention relates to a polymer which is useful as flame-retardant polymer. The invention also relates to a method of preparing said polymer and to a thermoplastic polymer composition comprising said polymer. The thermoplastic polymer composition can be used for the production of molded articles or yarns having excellent flame-retardant properties in order to ensure adequate fire protection.