Flame-Retardant Polypropylene Composition for Flexible Automotive Wires

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Solution Overview

Problem

Current polyolefin compositions used in automotive wires lack sufficient flame retardancy, cold flexibility, and abrasion resistance, particularly for thinner wires, and are often incompatible with environmental standards due to the use of halogen-based additives.

Innovation Solution

A flame retardant polypropylene composition comprising a heterophasic propylene copolymer with a polypropylene homo- or copolymer matrix and an ethylene propylene rubber dispersed within, combined with a coated metal hydroxide, which provides improved flame retardancy and mechanical properties without halogen or phosphorous-containing compounds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogen-based additives are used to improve flame retardancy, then flame resistance is improved, but environmental compatibility deteriorates due to poisonous and corrosive gases upon combustion

Engineering Contradiction:

Improveflame resistanceVSAvoidenvironmental compatibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of halogen-based flame retardants (releasing poisonous gases) into a beneficial alternative by using inorganic flame retardants that release non-toxic water vapor and carbon dioxide upon combustion, thus maintaining flame resistance while eliminating environmental harm

Inventive Principle:

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

Solution Approach 2:

The patent introduces inorganic flame retardants as an intermediary substance that mediates between the requirement for flame resistance and environmental compatibility, providing the necessary fire protection without the harmful side effects of halogen-based additives

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If polyolefin compositions are used to replace PVC, then environmental compatibility is improved, but flame retardancy deteriorates as polyolefins are inherently combustible

Engineering Contradiction:

Improveenvironmental compatibilityVSAvoidflame retardancy

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent creates a composite material system by combining polyolefin base resin with inorganic flame retardant particles, achieving both environmental compatibility and flame retardancy through the synergistic effect of the polymer matrix and inorganic filler

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the chemical composition parameters of the flame retardant system by replacing organic halogen-based compounds with inorganic substances, fundamentally altering the combustion behavior from releasing toxic gases to releasing non-toxic decomposition products

Inventive Principle:

Principle #35Parameter changes

3Temperature

If crosslinked polyethylene or polypropylene compositions are used to withstand temperatures up to 125°C, then heat resistance is improved, but processing complexity increases due to crosslinking requirements

Engineering Contradiction:

Improveheat resistanceVSAvoidprocessing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent uses thermoplastic polypropylene instead of crosslinked polymers, accepting that the material may degrade at very high temperatures in exchange for vastly simplified processing and manufacturing without crosslinking steps

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Ease of manufacture

If polypropylene is used as base resin, then processing properties are improved, but cold flexibility deteriorates as PP becomes brittle at around -5°C

Engineering Contradiction:

Improveprocessing propertiesVSAvoidcold flexibility

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent creates a composite structure where inorganic flame retardant particles are dispersed in the polypropylene matrix, and the specific composition and surface treatment of these particles prevent stress concentration that would otherwise cause brittleness at low temperatures

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 superior abrasion resistance and meets stringent specifications for needle abrasion, flame retardancy, and cold flexibility, including GM15626 and German standard LV112 requirements, while being environmentally friendly and cost-effective.

Implementation Method 1

a flame retardant polypropylene composition comprising a base resin and a coated metal hydroxide

Methodology Applied

Scientific EffectEndothermic Reaction: Endothermic Reaction

Implementation Method 2

coated metal hydroxide

Methodology Applied

Scientific EffectHydrates: Hydrates

Implementation Method 3

a base resin comprising a heterophasic propylene copolymer which comprises a polypropylene homo- or copolymer matrix

Methodology Applied

Scientific EffectCrystallisation: Crystallisation

Data Source

PatentEP3250659B1Flame retardant polypropylene composition

Publication Date: 2023.11.08 BOREALIS AG

AI summary

The present invention relates to a flame retardant polypropylene composition for a conduit, appliance, and/or automotive wire, comprising a flame retardant composition comprising: a) a base resin comprising a heterophasic propylene copolymer which comprises a polypropylene homo- or copolymer matrix and an ethylene propylene rubber dispersed in said matrix, and b) a metal hydroxide or hydrated compound, wherein the heterophasic propylene copolymer has a MFR2 below 0.8 g/10min and a xylene cold soluble (XCS) fraction content between 1 and 15 wt% based on the total weight of the heterophasic propylene copolymer.