Halogen-Free Flame Retardant Acrylic Polymers
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Solution Overview
Problem
Current flame retardant (meth)acrylic polymers used in cap layers are combustible and adversely affect physical and mechanical properties when increased levels are used to enhance flame resistance, and they often incorporate toxic halogenated compounds.
Innovation Solution
A blend of organic phosphinate and low levels of phosphonate ester compounds is used in a (meth)acrylic polymer composition to achieve synergistic flame retardancy without compromising mechanical properties, allowing for improved flame resistance, flowability, and reduced yellowness, while avoiding halogenated flame retardants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogenated flame retardant compounds are used to improve flame resistance, then flame retardancy is improved, but toxicity and adverse effects on physical properties occur
Solution Approach 1:
The patent replaces harmful halogenated flame retardants with beneficial non-halogenated alternatives (phosphorus-based compounds). The phosphorus-containing flame retardants provide equivalent or superior flame protection without the toxicity associated with halogenated compounds, converting a harmful approach into a beneficial one.
Solution Approach 2:
The patent changes the chemical composition parameters by switching from halogenated to non-halogenated flame retardant chemistry. Specifically, it uses phosphorus-based compounds (phosphates, phosphonates, phosphinic acids) instead of halogenated compounds, fundamentally altering the chemical parameter while maintaining or improving flame safety and eliminating toxicity.
2Reliability
If increased levels of flame retardant are used to improve flame resistance, then flame retardancy is improved, but physical and mechanical properties deteriorate
Solution Approach 1:
The patent optimizes the concentration parameter of flame retardants by using phosphorus-based compounds that achieve effective flame protection at lower loadings (5-20 parts by weight per 100 parts polymer) compared to traditional halogenated compounds. This parameter optimization maintains physical and mechanical properties while achieving the required flame retardancy.
Solution Approach 2:
The patent creates composite flame retardant systems by combining multiple phosphorus-based compounds (phosphates, phosphonates, phosphinic acids) in specific ratios. This composite approach provides synergistic effects that enhance flame protection while minimizing the total amount of flame retardant needed, thereby preserving the physical and mechanical properties of the polymer.
3Reliability
If increased levels of flame retardant are used to improve flame resistance, then flame retardancy is improved, but melt flow and elongation at break are reduced
Solution Approach 1:
The patent changes the chemical nature of flame retardants from halogenated to phosphorus-based compounds, which have different thermal and rheological properties. The phosphorus-based compounds provide flame protection while maintaining better melt flow characteristics, allowing for easier processing and manufacturing without the severe penalties associated with traditional flame retardants.
4Reliability
If halogenated flame retardants are used to achieve flame resistance, then flame retardancy is improved, but the composition becomes more complex and toxic
Solution Approach 1:
The patent extracts and removes the harmful halogenated components from the flame retardant composition. By taking out the toxic halogenated compounds and replacing them with phosphorus-based alternatives, the composition becomes simpler and less toxic while maintaining or improving flame safety.
Solution Approach 2:
The patent converts the harmful halogenated flame retardant system into a beneficial non-halogenated phosphorus-based system. This transformation eliminates the complexity and toxicity associated with halogenated compounds while providing equivalent or superior flame protection through the phosphorus chemistry.
Data Source
AI summary
The invention relates to a flame retardant (meth)acrylate composition combining an impact-resistant (meth)acrylic polymer (such as Solarkote® resin from Trinseo) with specific levels of selected organic phosphinate and selected organic phosphorous flame retardants. The composition is halogen free, with superior flame performance, flowability and impact resistance. The composition of the invention is melt-processible and can be co-extruded with a thermoplastic substrate material to obtain a multilayer structure, having a tough, impact resistant cap layer(s). The obtained multilayer structure can be further thermoformed into useful profiles and structures, such as the exterior housing of EV charging stations and car wash stations, automotive applications, aerospace, and building and construction applications.