Flame Retardant Resin Composition for Wire Coating
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Solution Overview
Problem
Current flame retardant resin compositions for wires and cables face challenges in achieving both flexibility and high flame retardant properties while being eco-friendly, as they often generate toxic gases or require excessive amounts of metal hydroxides, which can compromise physical properties and are restricted due to environmental concerns.
Innovation Solution
A non-halogen flame retardant resin composition is developed, comprising a blend of styrene copolymer and polyester elastomer, an epoxy resin, and a phosphor-based flame retardant agent, which improves flexibility and flame retardant properties without generating toxic substances, by forming char and enhancing heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-halogen coating material with metal hydroxide is used, then flame retardant properties are improved, but flexibility and tensile strength deteriorate due to excessive metal hydroxide content
Solution Approach 1:
The invention uses a composite resin system combining polyphenylene oxide (PPO) with specific elastomers (polyester elastomer, polyurethane elastomer, or acrylic elastomer) to create a balanced material that achieves flame retardancy while maintaining flexibility. The elastomer component compensates for the rigidity of PPO, providing the necessary physical properties for wire coating applications.
Solution Approach 2:
The invention optimizes the composition parameters by specifying precise weight ratio ranges: PPO content of 20-70 wt%, elastomer content of 30-80 wt%, and phosphor-based flame retardant agent of 1-30 wt%. This parameter optimization ensures both flame retardant performance and maintained flexibility without requiring excessive metal hydroxide.
2Reliability
If polyphenylene oxide is increased to attain flame retardant properties, then flame retardancy is improved, but flexibility deteriorates due to char formation and solid blocking layer
Solution Approach 1:
The invention creates a composite system where polyphenylene oxide (providing flame retardancy through char formation) is combined with elastomers (providing flexibility). This composite approach allows the material to exhibit both flame retardant properties and flexible characteristics, resolving the contradiction between these two properties.
Solution Approach 2:
The invention applies different functional components in specific proportions: PPO (20-70 wt%) for flame retardancy, elastomer (30-80 wt%) for flexibility, and phosphor-based flame retardant agent (1-30 wt%) for enhanced flame retardant effect. Each component contributes its specific property locally, achieving overall balance.
3Reliability
If halogen flame retardant agents are used, then flame retardant properties are improved, but harmful hydrogen halide is generated
Solution Approach 1:
The invention replaces harmful halogen-based flame retardants with a phosphor-based flame retardant agent that does not generate toxic gases. The phosphor-based agent works synergistically with polyphenylene oxide to achieve flame retardancy through char formation, converting the potential harm of halogen substances into a beneficial non-toxic alternative.
Solution Approach 2:
The invention uses readily available phosphor-based flame retardant agents and common elastomers as alternatives to expensive or restricted halogen-based materials, providing an economically viable and environmentally friendly solution that meets UL-1581 VW-1 standards.
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 effectively balances flexibility and flame retardancy, preventing dripping and ensuring compliance with stringent UL-1581 standards, while being environmentally friendly and avoiding the use of hazardous halogen-based materials.
Implementation Method 1
an epoxy resin contributing to the improvement of the flame retardant properties... an epoxy resin capable of forming char and improving flame retardant properties
Implementation Method 2
a phosphor-based flame retardant agent assisting the formation of the char
Implementation Method 3
polyphenylene oxide forms char to produce a solid blocking layer and the system thus produced blocks heat and oxygen
Data Source
AI summary
The present invention relates to a flame retardant resin composition including (A) 100 parts by weight of a blend resin composition including a styrene copolymer and a polyester elastomer, (B) 1 to 30 parts by weight of an epoxy resin, and (C) 1 to 30 parts by weight of a phosphor-based flame retardant agent. The flame retardant resin composition has improved flame retardant properties and flexibility and is used for coating a wire and a cable.