Flame-Retardant Gasket Rubber Composition With Low Adhesion
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Solution Overview
Problem
Existing ethylene-α-olefin-non-conjugated diene copolymer rubbers face issues with high adhesion to manufacturing equipment, increased hardness, and insufficient flame retardancy when using hydrated metal oxides and halogen-based compounds, which also pose environmental risks.
Innovation Solution
Incorporating an alkyl-modified silane coupling agent in a predetermined ratio with aluminum hydroxide, along with a plasticizer, to reduce adhesion and hardness while maintaining flame retardancy, using a composition comprising 60% aluminum hydroxide, 8% or less alkyl-modified silane coupling agent, and 8% or less total plasticizer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of hydrated metal oxide is added to achieve high flame retardancy, then flame retardancy is improved, but adhesion to manufacturing equipment increases and processability deteriorates
Solution Approach 1:
An alkyl-modified silane coupling agent is introduced as an intermediary substance between the hydrated metal oxide and the ethylene-α-olefin-non-conjugated diene copolymer. The silane coupling agent modifies the surface of the hydrated metal oxide particles, reducing their hydrophilicity and strong interaction with metals, thereby decreasing adhesion to manufacturing equipment while maintaining the flame retardant properties of the hydrated metal oxide.
Solution Approach 2:
The invention changes the surface properties parameter of the hydrated metal oxide by applying silane coupling agent treatment. This parameter change transforms the hydrophilic surface into a hydrophobic surface, which significantly reduces adhesion to metal surfaces of manufacturing equipment like molds and kneaders, thereby improving processability without sacrificing flame retardancy.
2Reliability
If a large amount of hydrated metal oxide is added to achieve high flame retardancy, then flame retardancy is improved, but hardness increases and suitability for sealing materials deteriorates
Solution Approach 1:
The alkyl-modified silane coupling agent acts as a intermediary that modifies the interface between hydrated metal oxide particles and the polymer matrix. By reducing the strong interaction between hydrated metal oxide and surrounding materials, the silane coupling agent prevents excessive hardening while maintaining the flame retardant function of the hydrated metal oxide filler.
Solution Approach 2:
The silane coupling agent changes the surface energy and wettability parameters of the hydrated metal oxide particles. This parameter change improves the compatibility between the filler and the polymer matrix, preventing agglomeration and excessive hardening, thereby maintaining suitable hardness for sealing material applications while achieving high flame retardancy.
3Reliability
If halogen-based flame retardants are used to achieve high flame retardancy with small amounts, then flame retardancy is improved, but environmental pollution increases due to toxic and corrosive halogen gases
Solution Approach 1:
The invention extracts and removes halogen-based flame retardants from the composition, replacing them with non-halogen alternatives (hydrated metal oxide combined with silane coupling agent). This extraction eliminates the source of toxic and corrosive halogen gases while maintaining effective flame retardancy through the modified hydrated metal oxide system.
Solution Approach 2:
The invention converts the traditionally harmful hydrophilic surface property of hydrated metal oxide into a benefit by using silane coupling agent modification. This transformation turns the strong metal interaction (which causes adhesion problems) into a controlled surface property that can be managed with small amounts of silane, enabling the use of environmentally friendly non-halogen flame retardants.
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 solution achieves excellent flame retardancy, low environmental impact, and suitable hardness for sealing materials, ensuring good releasability and compatibility with manufacturing equipment.
Implementation Method 1
an alkyl-modified silane coupling agent... the surface of the hydrated metal oxide is silane-treated to improve compatibility
Implementation Method 2
non-halogen and non-antimony flame retardants such as ammonium polyphosphate, hydrated metal oxides such as aluminum hydroxide and magnesium hydroxide
Data Source
AI summary
Provided is a flame-retardant rubber composition including an ethylene-α-olefin-non-conjugated diene copolymer, aluminum hydroxide, an alkyl-modified silane coupling agent, and a hydrocarbon-based plasticizer. An amount of the aluminum hydroxide is 60 mass % or more of the flame-retardant rubber composition, a total amount of the alkyl-modified silane coupling agent and the hydrocarbon-based plasticizer is 8 mass % or less of the flame-retardant rubber composition, and an amount of the alkyl-modified silane coupling agent is 5 mass % or more of the aluminum hydroxide. The flame-retardant rubber composition has excellent flame retardancy, physical properties suitable as a sealing material, and low environmental impact.