Halogen-Free Flame Retardant Polymer for Wire Insulation
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Solution Overview
Problem
Existing flame retardant polymer compositions for wires and cables lack excellent flame retardant properties while maintaining good mechanical properties, often rely on halogen compounds that are environmentally critical, and are difficult to process, with limited extruder output, especially when using aluminum trihydroxide.
Innovation Solution
A flame retardant polymer composition comprising 2.0 to 49.8 wt.% of a copolymer with ethylene units and methyl acrylate or methyl methacrylate, 0.1 to 6.0 wt.% of polyethylene or polypropylene containing maleic acid anhydride units, 0.1 to 5.0 wt.% of silicone fluid, 50.0 to 70.0 wt.% of magnesium hydroxide, and optionally 0 to 17.0 wt.% of a copolymer with C4 to C10 alpha olefin, providing a halogen-free, easily processable solution with enhanced mechanical and flame retardant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen compounds are used as flame retardants, then flame retardant properties are improved, but environmental friendliness deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters by completely replacing halogen compounds with magnesium hydroxide as the flame retardant agent. This parameter change achieves both flame retardancy (meeting EN50399 and EN60332-1 standards) and environmental friendliness (halogen-free formulation), resolving the contradiction between effective flame protection and environmental safety.
Solution Approach 2:
The patent creates a composite polymer material system combining polyethylene, polypropylene, and magnesium hydroxide in specific ratios. This composite approach integrates the flame retardant properties of magnesium hydroxide with the mechanical properties of the polymer matrix, achieving both fire safety and environmental compatibility without relying on harmful halogen compounds.
2Reliability
If aluminum trihydroxide is used as flame retardant filler, then flame retardant properties are improved, but processability and extruder output deteriorate
Solution Approach 1:
The patent changes the filler material parameter from aluminum trihydroxide to magnesium hydroxide. This substitution maintains excellent flame retardant performance while significantly improving processability and extruder output, as magnesium hydroxide has better flow characteristics and requires lower processing temperatures, thereby resolving the contradiction between fire safety and manufacturing efficiency.
3Reliability
If flame retardant filler content is increased, then flame retardant properties are improved, but mechanical strength deteriorates
Solution Approach 1:
The patent optimizes the filler content parameter by using magnesium hydroxide at 50-70 wt% of the total composition, which provides sufficient flame retardancy while maintaining acceptable mechanical properties. The specific particle size distribution and surface treatment of the magnesium hydroxide further enhance the mechanical strength, resolving the contradiction between fire protection and structural integrity.
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, good mechanical strength, and high extruder output, meeting stringent fire safety standards like EN50399 and EN60332-1, while being environmentally friendly and easy to process.
Implementation Method 1
The composition achieves excellent flame retardant properties... 50.0 to 70.0 wt.% of magnesium hydroxide
Implementation Method 2
A flame retardant polymer composition comprising 2.0 to 49.8 wt.% of a copolymer with ethylene units and methyl acrylate or methyl methacrylate
Implementation Method 3
0.1 to 5.0 wt.% of silicone fluid... easily processable solution with enhanced mechanical and flame retardant properties
Data Source
AI summary
The present invention relates to a flame retardant polymer composition comprising at least the following components A) 2.0 to 49.8 wt.-% based on the overall weight of the polymer composition of a copolymer comprising ethylene units and units selected from the group consisting of methyl acrylate, methyl methacrylate and mixtures thereof; B) 0.1 to 6.0 wt.-% based on the overall weight of the polymer composition of a polyethylene and/or polypropylene containing units originating from maleic acid anhydride; C) 0.1 to 5.0 wt.-% based on the overall weight of the polymer composition of a silicone fluid and/or a silicon gum; D) 50.0 to 70.0 wt.-% based on the overall weight of the polymer composition of a magnesium hydroxide; and E) 0 to 17.0 wt.-% based on the overall weight of the polymer composition of a copolymer of ethylene and a C4 to C10 alpha olefin comonomer having a density in the range of 860 kg/m3 to 950 kg/m3 determined according to ISO 1183; wherein the weight proportions of components A) to E) add up to 100 wt.-%. In addition, the present invention refers to a wire or cable comprising at least one layer comprising the polymer composition according to the present invention and to the use of the polyolefin composition according to the present invention as a flame retardant layer of a wire or cable.