Flame-Retardant Polyester Resin Composition with Phosphorus-Nitrogen Synergy
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Solution Overview
Problem
Thermoplastic polyester resins used in mechanical, electric, and automobile components face challenges in achieving high flame retardancy and tracking resistance without compromising mechanical properties, as existing solutions either lack sufficient tracking resistance or introduce toxic byproducts like dioxin due to halogen-based flame retardants.
Innovation Solution
A flame-retardant thermoplastic polyester resin composition incorporating 50-95 parts of thermoplastic polyester resin, 5-50 parts of methacrylate resin, 1-70 parts of phosphor-containing flame retardants (condensed phosphate ester, phosphazene compound, or organic metal phosphinate salt), and 1-90 parts of nitrogen-containing flame retardants, which are then molded into articles with enhanced tracking resistance and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen flame retardants are used to improve flame retardancy, then flame retardancy is improved, but toxic byproducts like dioxin are generated
Solution Approach 1:
The patent replaces harmful halogen flame retardants with non-halogen alternatives (phosphor-containing and nitrogen-containing compounds), converting the harmful effect into a beneficial one by achieving flame retardancy without toxic byproduct generation. The phosphor-nitrogen synergistic system provides effective flame suppression while eliminating dioxin formation.
Solution Approach 2:
The patent changes the chemical composition parameters by specifying precise weight ratios of phosphor-containing flame retardant (0.1-10 parts) and nitrogen-containing flame retardant (0.1-10 parts) relative to polybuthylene terephthalate (100 parts). This parameter optimization ensures high flame retardancy while maintaining non-halogen composition to avoid toxic emissions.
2Object-generated harmful factors
If non-halogen flame retardants are used to avoid toxic byproducts, then environmental safety is improved, but tracking resistance becomes insufficient
Solution Approach 1:
The patent creates a composite flame retardant system combining phosphor-containing compounds (first flame retardant) and nitrogen-containing compounds (second flame retardant) in specific ratios. This composite approach provides both adequate flame retardancy and improved tracking resistance, overcoming the limitations of single-component non-halogen flame retardants.
Solution Approach 2:
The patent introduces an intermediary mechanism where the phosphor-containing flame retardant forms a protective layer during burning, and the nitrogen-containing flame retardant works synergistically to enhance both flame retardancy and tracking resistance. This intermediary action prevents direct contact between electrical discharge and the base resin, improving tracking resistance.
3Reliability
If flame retardants are added to achieve high flame retardancy, then flame retardancy is improved, but mechanical properties are compromised
Solution Approach 1:
The patent optimizes the concentration parameters of flame retardants by limiting phosphor-containing flame retardant to 0.1-10 parts and nitrogen-containing flame retardant to 0.1-10 parts per 100 parts of polybuthylene terephthalate. This controlled dosing achieves high flame retardancy (V-0 rating) while minimizing the impact on mechanical properties through precise parameter management.
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 a balance between high flame retardancy and tracking resistance, forming a protective phosphor-containing flame retardant layer during burning, suitable for applications in machine, electric, and automobile components without generating toxic byproducts.
Implementation Method 1
incorporating a particular amount of (B) a methacrylate resin in (A) a thermoplastic polyester resin, and further incorporating a particular amount of (C) a phosphor-containing flame retardant... to thereby improve tracking resistance of the article molded therefrom
Data Source
AI summary
The present invention includes a flame-retardant thermoplastic polyester resin composition which provides a molded article having excellent tracking resistance and excellent mechanical characteristics, while maintaining high flame retardancy; and a molded article which is obtained by molding the flame-retardant thermoplastic polyester resin composition. A flame-retardant thermoplastic polyester resin composition of an embodiment of the present invention contains 1-70 parts by weight of two or more (C) phosphorus-containing flame retardants that are selected from the group consisting of (C-1) condensed phosphoric acid esters, (C-2) phosphazene compounds and (C-3) organic metal phosphinates and 1-90 parts by weight of (D) a nitrogen-containing flame retardant per 100 parts by weight of the total of 50-95 parts by weight of (A) a thermoplastic polyester resin and 5-50 parts by weight of (B) a methacrylic resin.