Flame-Retardant Resin Composition for Electric Wire Coatings
Solution Overview
Problem
Existing flame-retardant resin compositions for electric wires and cables face challenges in achieving high productivity, flexibility, and flame retardancy while preventing bleed out and migration of components, especially when in contact with other resins like ABS.
Innovation Solution
A resin composition comprising polyphenylene ether, a hydrogenated copolymer with an aromatic vinyl monomer and conjugated diene monomer unit, and a metal phosphinate, with specific weight ratios and molecular weights to ensure high flame retardancy, flexibility, and resistance to bleed out and migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the content of polyphenylene ether is reduced to improve flexibility and productivity, then flexibility and productivity are improved, but flame retardancy is reduced
Solution Approach 1:
The patent changes the chemical composition parameters by introducing a hydrogenated copolymer containing aromatic vinyl and conjugated diene units, replacing part of the polyphenylene ether. This parameter change maintains flame retardancy through the aromatic structure while improving flexibility and productivity through the copolymer's molecular characteristics
Solution Approach 2:
The patent creates a composite resin system combining polyphenylene ether, hydrogenated copolymer, and flame retardant additives. This composite approach leverages the flame retardancy of polyphenylene ether, the flexibility of the hydrogenated copolymer, and the flame-inhibiting properties of additives to achieve balanced performance
2Reliability
If the total content of flame retardant is increased to improve flame retardancy, then flame retardancy is improved, but bleed out of flame retardant occurs with elapsed time
Solution Approach 1:
The patent uses the hydrogenated copolymer as an intermediary carrier for the flame retardant. The copolymer's molecular structure interacts with the flame retardant to reduce its mobility and prevent bleed-out, while still allowing the flame retardant to function effectively
Solution Approach 2:
The patent optimizes the particle size and surface treatment parameters of the flame retardant additives, and adjusts their concentration within a specific range. These parameter changes reduce the tendency for bleed-out while maintaining effective flame retardancy
3Reliability
If flame retardant and plasticizer are added to achieve flame retardancy and flexibility, then flame retardancy and flexibility are improved, but migration to other resins such as ABS occurs causing defective appearance
Solution Approach 1:
The hydrogenated copolymer acts as an intermediary that reduces the migratory tendency of flame retardants and plasticizers. Its molecular structure creates a barrier effect that prevents these components from migrating to adjacent ABS resins, eliminating the defective appearance problem
Data Source
AI summary
The present invention provides a resin composition that simultaneously (1) supports high productivities, (2) is resistant to bleed out by the flame retardant present in the composition, (3) is resistant to migration of its components to another resin, (4) exhibits a high flame retardancy, and (5) exhibits high flexibility. The resin composition includes components (A) a polyphenylene ether, (B) a hydrogenated copolymer, (C) a styrene resin and/or olefin resin, and (D) a metal phosphinate, wherein the component (B) includes (B1) a polymer block principally comprising an aromatic vinyl monomer unit, and (B2) a hydrogenated copolymer block principally comprising an aromatic vinyl monomer unit and a conjugated diene monomer unit, and a content of the aromatic vinyl monomer unit in the (B2) is 20 to 95% by weight, and a content of the aromatic vinyl monomer unit in the (B) is 35 to 80% by weight.