Glow Wire Resistant Polyester Molding Compound
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current polymer materials used in household appliances lack sufficient glow-wire resistance, particularly in achieving the required ignition temperature of over 750°C to comply with IEC 60695-2-12 and -13 standards, and there is a need for materials that are easy to process and can be subjected to the Laser Direct Structuring (LDS) process while maintaining mechanical values.
Innovation Solution
Development of glow-wire-resistant polyester molding compounds containing copper chromite (CuCr2O4) combined with antimony-containing functional additives such as sodium antimonate or antimony trioxide, and organic bromine compounds like tetrabromobisphenol A epoxy oligomer or polypentabromobenzyl acrylate, which provide enhanced heat and fire resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymer materials are used, then processing ease and mechanical properties are maintained, but glow-wire resistance (ignition temperature) is insufficient to meet IEC 60695 standards
Solution Approach 1:
The patent employs composite materials by combining polyester base resin with multiple flame retardant additives (copper chromite, antimony trioxide, brominated compounds) to achieve the required glow-wire resistance while maintaining processability. This composite approach allows the material to meet IEC 60695 standards without sacrificing manufacturing ease.
2Reliability
If flame retardant additives are added to improve glow-wire resistance, then fire safety standards are met, but mechanical properties and processability deteriorate
Solution Approach 1:
The patent optimizes the concentration parameters of flame retardant additives to achieve the desired fire safety performance while minimizing negative impacts on mechanical properties. By carefully controlling the amounts of copper chromite, antimony trioxide, and brominated compounds, the formulation maintains adequate mechanical strength and processability.
Solution Approach 2:
The synergistic composite system combines multiple flame retardant mechanisms (copper chromite for heat resistance, antimony trioxide for char formation, brominated compounds for flame inhibition) to achieve superior fire safety while distributing the load on mechanical properties, preventing any single additive from excessively degrading strength.
3Reliability
If high concentration of flame retardants is used to achieve GWIT > 750°C, then fire resistance improves, but material homogeneity and processing quality deteriorate
Solution Approach 1:
The patent adjusts the concentration parameters of flame retardant additives to achieve the desired fire safety performance while minimizing negative impacts on mechanical properties and material homogeneity.
Solution Approach 2:
The patent employs masterbatch technology to pre-disperse flame retardant additives in a carrier resin before compounding with the polyester base resin. This preliminary action ensures uniform distribution of additives, preventing aggregation and maintaining material homogeneity even at high flame retardant concentrations required for GWIT > 750°C.
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 resulting materials exhibit improved glow-wire ignition temperature (GWIT) and flammability index (GWFI), achieving compliance with IEC 60695-2-12 and -13 standards, while also being suitable for the LDS process, ensuring both safety and processing ease.
Implementation Method 1
glow-wire-resistant polyester molding compounds containing copper chromite (CuCr2O4) and at least one antimony-containing functional additive... in combination with at least one organic bromine compound
Implementation Method 2
can be subjected to the LDS process as finished components... suitable for the LDS process
Data Source
AI summary
Glow-wire polyester molding composition comprises copper chromite and at least one antimony-containing functional additive (including sodium antimonate, antimony trioxide or antimony pentoxide) in combination with at least one organic bromine compound (including N,N-ethylene bis (tetrabromophthalimide), epoxidized tetrabromobisphenol A-resin, tetrabromobisphenol A-oligocarbonate, pentabromopolyacrylate, polypentabromobenzyl acrylate, brominated polystyrene, decabromodiphenylether or decabromodiphenyl ethane). An independent claim is included for an injection molded, three-dimensional circuit board obtained by injection molding the glow-wire polyester molding composition and subsequently subjecting to laser direct structuring.