Graphene Nanoplatelet Flame Retardant Composition

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Solution Overview

Problem

Current flame retardant compositions using graphene are either ineffective in small quantities or require the use of expensive and hazardous organic solvents due to graphene's hydrophobic nature, posing safety and environmental concerns, especially when applied to polymeric materials.

Innovation Solution

A flame retardant composition comprising graphene nanoplatelets and a condensation product of a sulfonated aromatic compound with formaldehyde, where the graphene to condensation product weight ratio ranges from 1:15 to 4:1, allowing for a water-based dispersion that can be easily applied as a coating or mixed with polymers, enhancing flame resistance without the need for organic solvents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If graphene is used as a flame retardant additive, then flame retardancy is improved, but the composition requires expensive and hazardous organic solvents due to graphene's hydrophobic nature

Engineering Contradiction:

Improveflame retardancyVSAvoiduse of organic solvents

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses a surfactant as an intermediary substance to bridge the hydrophobic graphene and hydrophilic water, enabling the formation of a stable water-based dispersion without requiring organic solvents. The surfactant molecules adsorb onto the graphene surface, providing hydrophilic groups that interact with water while the hydrophobic portions interact with graphene, thus resolving the solubility contradiction.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the physical-chemical parameters of the dispersion system by adjusting surfactant concentration, graphene concentration, and ultrasonic treatment parameters to achieve a stable water-based dispersion. This transforms the system from requiring organic solvents to using water as the primary medium, eliminating the harmful effects while maintaining flame retardancy.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If graphene is dispersed in water without surfactants, then organic solvents are eliminated, but the dispersion stability is poor due to graphene's hydrophobic nature

Engineering Contradiction:

Improveelimination of organic solventsVSAvoiddispersion stability

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The surfactant acts as a mediator between water and hydrophobic graphene, enabling stable dispersion. The surfactant molecules form a protective layer around graphene sheets, preventing aggregation and improving dispersion stability while maintaining water as the base medium, thus avoiding organic solvents.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a composite dispersion system comprising graphene, surfactant, and water, where the surfactant-graphene complex forms a stable colloidal system. This composite approach combines the flame retardancy of graphene with the dispersion stability provided by the surfactant-watex system.

Inventive Principle:

Principle #40Composite materials

3Reliability

If high concentrations of graphene are used to achieve effective flame retardancy, then flame protection is improved, but the coating weight and material cost increase

Engineering Contradiction:

Improveflame protectionVSAvoidcoating weight

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent utilizes the two-dimensional sheet structure of graphene to create highly effective thin-film coatings. The large surface area-to-volume ratio of graphene sheets allows for effective flame barrier properties at very low concentrations, forming protective thin films that prevent further weight increase while maintaining excellent flame protection.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent optimizes the concentration parameters of graphene and surfactant to achieve maximum flame retardancy efficiency. By carefully controlling these parameters, the formulation achieves effective flame protection at reduced graphene concentrations, minimizing coating weight while maintaining performance.

Inventive Principle:

Principle #35Parameter changes

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 passes stringent flammability tests such as UL94HB and UL94V, providing excellent flame retardancy even at reduced coating weights, thus addressing safety and environmental concerns while maintaining performance.

Implementation Method 1

a condensation product of a sulfonated aromatic compound with formaldehyde... allowing for a water-based dispersion

Methodology Applied

Scientific EffectSurfactant action: Surfactant

Implementation Method 2

flame retardant composition... effectively passes stringent flammability tests such as UL94HB and UL94V, providing excellent flame retardancy

Methodology Applied

Scientific EffectFlame retardancy:

Data Source

PatentEP3033406B1Flame retardant composition comprising graphene nanoplatelets

Publication Date: 2020.02.26 DIRECTA PLUS

AI summary

A flame retardant composition comprising graphene nanoplatelets and a condensation product of a sulfonated aromatic compound with formaldehyde, wherein the w/w ratio between the graphene and the condensation product is in the range of 1:15 to 4:1. The composition may be in the form of a water dispersion applied to the surface of the article to be treated. The composition has optimal flame retardant properties even when applied in relatively modest quantities.