Halogen-Free Flame Retardant Polymer Cable Composition
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Solution Overview
Problem
Existing flame retardant polymer compositions for electrical cables face challenges in meeting stringent safety and mechanical property requirements, particularly in resisting crushing and horizontal flame tests, with halogen-free systems often compromising on processability and mechanical strength, and requiring additional crosslinking steps, while also emitting harmful gases and exhibiting dripping behavior during fires.
Innovation Solution
A flame retardant polymer composition comprising a crosslinkable terpolymer with ethylene monomer units, silane group containing comonomer units, and polar group comonomer units, combined with a metal carbonate filler and silicone fluid or gum, which enhances mechanical and flame retardant properties without harmful gas emissions and eliminates the need for additional crosslinking agents, thereby improving crushing resistance and preventing dripping during fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large amounts of inorganic fillers (50-60 wt%) are added to achieve high flame retardant properties in halogen-free polymer compositions, then flame retardancy is improved, but processability and mechanical properties deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the polymer matrix by incorporating polar groups (such as carboxyl, hydroxyl, or amine groups) into the polymer structure. This modification enhances the interaction between the polymer and filler particles, allowing for effective flame retardant performance with reduced filler content, thereby improving processability while maintaining reliability
Solution Approach 2:
The patent creates a composite material system combining modified polymer matrix with inorganic fillers. The composite structure leverages the synergistic effects between the polar-modified polymer and filler particles to achieve flame retardancy with lower filler loading, thus resolving the contradiction between flame safety and manufacturing ease
2Reliability
If large amounts of inorganic fillers (50-60 wt%) are added to achieve high flame retardant properties, then flame retardancy is improved, but mechanical properties deteriorate
Solution Approach 1:
By modifying the polymer matrix with polar groups, the patent changes the interfacial adhesion parameters between polymer and filler. This enhancement in adhesion allows the composite to maintain mechanical integrity with reduced filler content, thus preserving mechanical properties while achieving flame retardancy
Solution Approach 2:
The composite material design with polar-modified polymer creates a more homogeneous and strongly bonded structure. This composite approach distributes stress more effectively and prevents filler aggregation, maintaining mechanical strength at lower filler loadings required for flame safety
3Reliability
If additional crosslinking agents are added to CaSiCo systems to meet UL44 standards, then flame retardant properties are improved, but device complexity and processing steps increase
Solution Approach 1:
The patent combines the flame retardant functionality and crosslinking functionality into a single integrated polymer system. The polar-modified polymer matrix inherently provides both flame retardant properties and crosslinking capability, eliminating the need for separate crosslinking agents and reducing processing complexity while maintaining reliability
4Reliability
If halogen compounds are added to improve flame retardancy, then flame retardant properties are improved, but harmful gas emissions increase
Solution Approach 1:
The patent converts the traditional approach of using harmful halogen compounds into a beneficial halogen-free system. By employing polar-modified polymers with inorganic fillers, the system achieves flame retardancy through a mechanism that does not produce harmful gases, thus converting the harm of traditional flame retardants into a benefit of environmentally safe flame protection
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 flame retardant properties and mechanical strength, meeting UL44 and TUV 2Pfg 1169/08.2007 standards, with no harmful gas emissions and improved crushing resistance, making it suitable for photovoltaic cables and electrical devices.
Implementation Method 1
a crosslinkable terpolymer comprising ethylene monomer units, a silane group containing comonomer units
Implementation Method 2
a crosslinkable terpolymer comprising ethylene monomer units, a silane group containing comonomer units
Implementation Method 3
add large amounts, typically 50 to 60 wt% of inorganic fillers such as hydrated and hydroxy compounds. Such fillers, which include Al(OH)3 and Mg(OH)2 decomposes endothermically at temperatures between 200 and 600°C, liberating inert gases
Data Source
AI summary
The present invention relates to a flame retardant polymer composition comprising a crosslinkable terpolymer comprising ethylene monomer units, a silane group containing comonomer units and comonomer units comprising a polar group; a metal carbonate filler and a silicone fluid or gum; wherein the content of the comonomer units comprising a polar group is between 2 and 25wt% of the terpolymer and the content of the silane group containing comonomer units is between 0.2 and 4 wt% of the terpolymer. The present invention is also directed to the process for the production of the polymer composition, to a cable and/or to an electrical device having a layer comprising said polymer composition, and uses thereof.