Flame-Retardant Epoxy Resin Composition with Phosphorus Crosslinking
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Solution Overview
Problem
Conventional flame-retardant epoxy resin compositions face issues such as the bleed phenomenon of flame retardants and decreased physical and thermal properties of cured materials, particularly when using phosphorus-containing compounds with limited reaction points, which affect workability and environmental adaptability.
Innovation Solution
A flame-retardant epoxy resin composition incorporating a phosphorous compound with multiple reaction points, as expressed by the general formula (C), which reacts with the epoxy resin to prevent bleed and maintain excellent physical and thermal properties, while being environmentally friendly by avoiding halogen use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a phosphorus-containing compound with high phosphorus content is added to achieve flame retardancy, then flame retardant effect is improved, but bleed phenomenon occurs and Tg value decreases
Solution Approach 1:
The invention changes the chemical structure parameters of the phosphorus-containing compound by introducing multiple epoxy reaction points (at least two epoxy groups or rings) in the molecular structure. This structural parameter change enables the compound to react with epoxy resin through multiple points, forming a crosslinked network that prevents bleed while maintaining flame retardancy. The patent specifies that the phosphorus-containing compound must have at least two epoxy groups or rings, which fundamentally alters how the compound interacts with the epoxy resin system.
Solution Approach 2:
The invention creates a composite flame-retardant system by combining the phosphorus-containing compound with epoxy resin and curing agents. The phosphorus-containing compound serves as a multifunctional component that simultaneously provides flame retardancy, reacts with epoxy resin through multiple epoxy groups, and forms an integrated crosslinked structure. This composite approach eliminates the need for separate flame retardant additives that cause bleed, as the phosphorus compound becomes an integral part of the cured epoxy network.
2Stability of the object's composition
If a phosphorus-containing compound with one reaction point is used to react with epoxy resin, then bleed phenomenon is prevented, but physical properties and thermal resistance decrease
Solution Approach 1:
The invention changes the functionality parameter of the phosphorus-containing compound from one reaction point to multiple reaction points (at least two epoxy groups or rings). This parameter change transforms the compound from a simple additive into a multifunctional crosslinking agent that can form multiple bonds with epoxy resin, thereby maintaining physical properties and thermal resistance while preventing bleed phenomenon through covalent bonding.
Solution Approach 2:
The invention creates a crosslinked composite structure where the phosphorus-containing compound with multiple epoxy groups forms an integrated network with the epoxy resin. This composite structure combines the benefits of chemical bonding (preventing bleed) with enhanced crosslinking density (maintaining strength and thermal resistance). The multifunctional phosphorus compound acts as both a flame retardant and a crosslinking agent in this composite system.
3Reliability
If a phosphorus-containing compound with high crystalline properties is used, then flame retardancy is achieved, but workability of the composition deteriorates
Solution Approach 1:
The invention changes the physical state parameter of the phosphorus-containing compound by designing it with multiple epoxy groups that enable strong interaction with epoxy resin. This chemical interaction prevents crystallization and maintains the compound in a soluble, processable state during composition preparation and application. The multiple epoxy groups ensure the compound remains compatible with the resin system, providing excellent workability while maintaining flame retardancy in the cured state.
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 composition achieves excellent workability, physical properties, and thermal resistance in cured materials, along with enhanced environmental adaptability and flame retardancy, making it suitable for applications like laminated plates and electronic components.
Implementation Method 1
a phosphorous compound (C) expressed by the following general formula (1) which has two or more reaction points capable of reacting with an epoxy group
Data Source
AI summary
A flame-retardant epoxy resin composition wherein (A) epoxy resin, (B) a curing agent and (C) a phosphorous-containing compound expressed by the following general formula (1) are contained; a prepreg using the same and a laminated plate using said prepreg; wherein m expresses an integer from 2 to 10, R1 and R2 each independently express an alkyl group or an aryl group, R3 expresses a hydrocarbon group that may contain an oxygen atom, a sulfur atom or a nitrogen atom, X expresses an oxygen atom or a sulfur atom, Y expresses an oxygen atom, a sulfur atom or -NR4-, and in this regard, R4 expresses a hydrogen atom, an alkyl group or an aryl group.