Coextruded Flame-Retardant Coating on Recyclable Plastic Substrate
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Solution Overview
Problem
Current extruded plastic parts used in the electrical industry for cable management and protection face challenges such as the need for halogenated flame retardants, which are toxic, environmentally harmful, and non-recyclable, while alternatives like PVC are questioned due to smoke production and health concerns, and other materials like PLA are prone to premature degradation.
Innovation Solution
An extruded part with a core-skin structure comprising a thermoplastic polymer substrate and a non-halogenated flame retardant layer made of polyolefin and ammonium polyphosphates, where the flame retardant layer adheres to the substrate, ensuring excellent adhesion and surface functionalization for fire resistance without halogenated compounds, and the substrate is preferably derived from recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogenated flame retardants are incorporated in the mass of plastic parts, then fire resistance properties are achieved, but health and environmental concerns arise and recyclability is compromised
Solution Approach 1:
The patent divides the plastic part into two segments: a substrate made of recyclable thermoplastic polymer and a separate flame retardant coating layer applied to its surface. This segmentation allows the flame retardant properties to be achieved without incorporating toxic halogenated compounds into the bulk plastic material, thereby maintaining recyclability while reducing health and environmental hazards.
Solution Approach 2:
The flame retardant function is extracted from the bulk plastic material and relocated to a surface coating layer. This extraction eliminates the need to incorporate halogenated flame retardants throughout the plastic mass, allowing the substrate to remain free of toxic substances and maintain its recyclability while the coating provides the required fire resistance.
2Reliability
If non-halogenated flame retardants like ammonium polyphosphates and metal hydroxides are used in the plastic mass, then fire resistance is achieved without halogenated compounds, but mechanical properties are altered and tool corrosion occurs
Solution Approach 1:
The patent segments the flame retardant function from the structural substrate, placing non-toxic flame retardant compounds in a surface coating rather than incorporating them into the bulk plastic. This prevents the degradation of mechanical properties and tool corrosion that would result from adding flame retardants to the plastic mass.
3Reliability
If flame retardants are distributed throughout the entire volume of the plastic part, then uniform fire resistance is achieved, but recyclability is prevented due to toxic additives
Solution Approach 1:
The patent segments the plastic part into a recyclable substrate and a flame retardant coating layer. The substrate can be recycled independently without toxic contaminants, while the coating provides the necessary fire resistance. This segmentation resolves the contradiction between achieving uniform fire protection and maintaining recyclability.
Solution Approach 2:
The flame retardant function is extracted from the recyclable plastic substrate and placed in a separate coating layer. This extraction allows the substrate to maintain its recyclability while the coating provides the required fire resistance properties.
4Reliability
If PVC is used for extruded plastic parts, then fire resistance is achieved, but smoke production and health concerns increase
Solution Approach 1:
The patent extracts the fire resistance function from PVC and relocates it to a surface coating layer. This allows the use of recyclable thermoplastic polymers free from halogenated compounds and smoke-producing additives in the substrate, while the coating provides the necessary fire resistance without generating harmful smoke.
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 solution provides superior fire resistance, improved recyclability, reduced environmental impact, and enhanced durability, meeting stringent fire resistance standards while avoiding the drawbacks of halogenated flame retardants and PVC, with the flame retardant layer being removable at the end of life, thus improving end-of-life plastic part management.
Implementation Method 1
a flame-retardant layer of a flame-retardant material coating the substrate so that the outer surface of the part is composed solely of said flame retardant material, wherein the flame retardant layer adheres to the substrate
Data Source
AI summary
An extruded part comprising a substrate including at least one thermoplastic polymer, and a flame-retardant layer of a flame-retardant material encapsulating the substrate such that the external surface of the part is composed solely of said flame-retardant material, wherein the flame-retardant layer adheres to the substrate, the flame-retardant material comprising a polyolefin and a non-halogenated flame-retardant compound, and the substrate comprising a mixture of a polyolefin and at least one thermoplastic biopolymer and/or at least one thermoplastic polymer, and a compatibilizing agent for the thermoplastic biopolymer and/or the thermoplastic polymer with the polyolefin. A method for preparing said part by coextrusion. This part may, in particular, be selected from parts intended for the management and/or protection of cables and cable systems, such as cable trays and raceways.