Flame-Retardant Polyolefin Composition With Better Surface and Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flame retardant polymer compositions for wires and cables fail to combine excellent flame retardation, smooth shiny surface properties, and good mechanical properties, while also being environmentally friendly and easy to process.
Innovation Solution
A flame retardant polymer composition comprising 15.0 to 25.0 wt% of a copolymer of ethylene and alpha olefin comonomer units, 20.0 to 35.0 wt% of another copolymer with specific density and melt flow rate, 0.5 to 4.0 wt% of polyethylene or polypropylene with maleic acid anhydride units, 40.0 to 60.0 wt% of magnesium hydroxide, and 0.1 to 3.0 wt% of silicon fluid or silicone gum, all based on the overall weight of the polymer composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If calcium borate and aluminum hydroxide are used as flame retardants, then flame retardant properties are improved, but mechanical properties deteriorate and toxicity increases
Solution Approach 1:
The patent changes the chemical composition parameters by replacing calcium borate and aluminum hydroxide with magnesium hydroxide as the flame retardant. This substitution maintains flame retardant effectiveness while improving mechanical properties and eliminating toxicity concerns associated with borates
Solution Approach 2:
The patent creates a composite polymer composition combining polyolefin base polymers with magnesium hydroxide flame retardant and specific additives. This composite approach achieves synergistic effects where the flame retardant properties are maintained or improved while mechanical properties are enhanced compared to conventional formulations
2Reliability
If halogen or borate compounds are used as flame retardants, then flame retardant properties are improved, but environmental friendliness deteriorates
Solution Approach 1:
The patent converts the traditionally harmful halogen and borate compounds into beneficial magnesium hydroxide, which provides flame retardancy through a environmentally friendly mechanism. Magnesium hydroxide decomposes to form a protective layer and releases water vapor, eliminating the toxic emissions associated with halogenated flame retardants
Solution Approach 2:
The patent changes the chemical composition by eliminating halogen and borate compounds entirely, replacing them with magnesium hydroxide. This parameter change transforms the environmental profile from harmful to benign while maintaining flame retardant functionality
3Reliability
If aluminum trihydroxide is used as flame retardant, then flame retardant properties are improved, but extruder output and processability deteriorate
Solution Approach 1:
The patent changes the flame retardant material from aluminum trihydroxide to magnesium hydroxide, which has different rheological properties. This substitution improves extruder output and processability while maintaining effective flame retardancy
4Reliability
If conventional flame retardant polymer compositions are used, then flame retardant properties are achieved, but surface properties and mechanical properties cannot be simultaneously optimized
Solution Approach 1:
The patent develops a composite formulation combining polyolefin base polymers with magnesium hydroxide, specific copolymers, and carefully selected additives. This composite structure achieves synergistic effects that simultaneously provide excellent flame retardancy, smooth shiny surface properties, and good mechanical characteristics
Solution Approach 2:
The patent applies different functional components in specific proportions and distributions within the polymer matrix. The formulation includes specific copolymers with controlled comonomer content and particle size distributions of magnesium hydroxide to optimize local properties for surface quality while maintaining bulk flame retardancy
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 polymer composition achieves excellent flame retardant properties, good surface properties, and enhanced mechanical properties, including high elongation at break and tensile strength, while being environmentally friendly and easy to process.
Implementation Method 1
40.0 to 60.0 wt% of magnesium hydroxide
Implementation Method 2
magnesium hydroxide
Implementation Method 3
0.1 to 3.0 wt% of silicon fluid or silicone gum
Data Source
AI summary
The present invention relates to a flame retardant polymer composition comprising (A) 15.0 to 25.0 wt% (based on the overall weight of the polymer composition) of a copolymer of ethylene and alpha olefin comonomer units having from 4 to 10 carbon atoms, which has a density of from 800 to 920 kg/m3 (ISO 1183); (B) 20.0 to 35.0 wt% (based on the overall weight of the polymer composition) of a copolymer of ethylene and alpha olefin comonomer units having from 4 to 10 carbon atoms, which has a density of from 930 to 980 kg/m3 (ISO 1183), and a melt flow rate MFRs of from 0.05 to 2.50 g/10 min (ISO 1133 at 190°C and a load of 5.0 kg); (C) 0.5 to 4.0 wt% (based on the overall weight of the polymer composition) of a polyethylene and/or polypropylene containing units originating from maleic acid anhydride; (D) 40.0 to 60.0 wt% (based on the overall weight of the polymer composition) of a magnesium hydroxide having a purity of ≥ 95 wt%, (E) 0.1 to 3.0 wt% (based on the overall weight of the polymer composition) of a silicon fluid and/or silicone gum; and optionally further additives, wherein the sum of all ingredients adds always up to 100 wt%. In addition, the present invention also relates to an article comprising said composition.