Flame Retardant Thermoplastic Elastomer Composition

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Solution Overview

Problem

Thermoplastic polyetherester elastomer compositions require flame retardancy without using halogenated materials, which decompose at processing temperatures, causing equipment corrosion and poor surface appearance in molded articles, and existing solutions fail to retain physical properties after heat aging.

Innovation Solution

A flame retardant thermoplastic elastomer composition comprising 70-99% melt-processable thermoplastic vulcanizate with a thermoplastic polyester continuous phase and poly(meth)acrylate or polyethylene/(meth)acrylate rubber disperse phase, dynamically cross-linked with a peroxide free-radical initiator and organic multiolefinic co-agent, combined with 1-30% non-halogenated phosphinate or disphosphinate flame retardants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogenated flame retardants are used to achieve flame retardancy, then flame retardant performance is improved, but equipment corrosion and poor surface appearance occur due to decomposition at processing temperatures

Engineering Contradiction:

Improveflame retardant performanceVSAvoidequipment corrosion and surface degradation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameter by substituting halogenated flame retardants with non-halogenated alternatives (phosphinate salts, disphosphinate salts, or polymers thereof), which do not decompose at processing temperatures and therefore eliminate equipment corrosion and surface degradation while maintaining flame retardant performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the harmful effect of flame retardant decomposition into a beneficial outcome by selecting flame retardant compounds (non-halogenated phosphinate/disphosphinate salts) that are thermally stable and do not decompose at processing temperatures, thereby eliminating corrosion and surface defects while maintaining effective flame retardancy

Inventive Principle:

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

2Reliability

If conventional flame retardant compositions are used, then flame retardancy is achieved, but physical properties deteriorate after heat aging in air

Engineering Contradiction:

Improveflame retardancyVSAvoidretention of physical properties after heat aging

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent creates a composite material system combining thermoplastic polyetherester elastomers with specific non-halogenated flame retardants (phosphinate salts, disphosphinate salts, or polymers thereof) at optimized concentrations (1-30 weight percent), where the flame retardant compounds provide both flame retardancy and thermal stability, preventing deterioration of physical properties after heat aging while maintaining effective flame retardant performance

Inventive Principle:

Principle #40Composite materials

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 good retention of physical properties after heat aging and excellent flame retardancy, making it suitable for high-temperature applications like automotive cables and appliance components without the drawbacks of halogenated flame retardants.

Implementation Method 1

at least one poly(meth)acrylate or polyethylene/(meth)acrylate rubber disperse phase wherein said rubber is dynamically cross-linked with at least one peroxide free-radical initiator

Methodology Applied

Scientific EffectFree-radical initiator cross-linking:

Implementation Method 2

about 1 to about 30 weight percent, of at least one flame retardant comprising a phosphinate of the formula (I) and/or a disphosphinate of the formula (II)

Methodology Applied

Scientific EffectFlame retardancy through phosphinate/disphosphinate action:

Data Source

PatentUS7790790B2Flame retardant thermoplastic elastomer compositions

Publication Date: 2010.09.07 CELANESE POLYMERS HLDG INC

AI summary

Flame retardant thermoplastic elastomer composition comprising a thermoplastic vulcanizate composition and non-halogenated flame retardant.