Halogen-Free Flame Retardant Polyolefin Composition

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current flame retardant systems for polyolefins do not meet all necessary safety and regulatory requirements, particularly in terms of reduced smoke density and toxicity associated with fire, and require higher concentrations of halogenated compounds and antimony oxide, which are environmentally undesirable.

Innovation Solution

A halogen-free or halogen-reduced flame retardant composition comprising a specific phosphonate ester and a synergist combination of N-alkoxy hindered amine and melamine cyanurate, which achieves effective flame retardancy at lower loading levels and improves thermal and light stability while reducing the need for antimony oxide and brominated flame retardants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogenated flame retardants and antimony oxide are used to achieve flame retardancy, then flame retardant performance is improved, but environmental safety and smoke density are worsened

Engineering Contradiction:

Improveflame retardant performanceVSAvoidsmoke density and toxicity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by using phosphonate esters with specific structures (formula 1) combined with melamine cyanurate and N-alkoxy hindered amine synergists, replacing traditional halogenated compounds. This parameter change achieves effective flame retardancy while eliminating the harmful smoke and toxicity associated with halogenated flame retardants.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite flame retardant system combining phosphonate ester, melamine cyanurate, and N-alkoxy hindered amine synergist. This composite material approach provides synergistic effects that enhance flame retardant performance while maintaining environmental safety, overcoming the limitations of single-component halogenated systems.

Inventive Principle:

Principle #40Composite materials

2Reliability

If higher concentrations of flame retardant additives are used to improve flame retardancy, then flame retardant performance is improved, but mechanical properties and processing stability are worsened

Engineering Contradiction:

Improveflame retardant performanceVSAvoidmechanical properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent optimizes the concentration parameters of flame retardant additives, achieving effective flame retardancy at lower loading levels due to the synergistic interaction between phosphonate ester and melamine cyanurate with N-alkoxy hindered amine. This reduced concentration level preserves the mechanical properties of the polyolefin substrate while maintaining excellent flame retardant performance.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional flame retardant systems are used to achieve flame retardancy, then flame retardant performance is improved, but thermal and light stability are worsened

Engineering Contradiction:

Improveflame retardant performanceVSAvoidthermal and light stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent changes the chemical structure parameters of the flame retardant system by selecting phosphonate esters with specific R1 and R2 groups (alkyl, benzyl, phenyl, or naphthyl) combined with melamine cyanurate and N-alkoxy hindered amine synergists. This structural optimization provides both effective flame retardancy and enhanced thermal and light stability, overcoming the degradation issues of conventional systems.

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 significantly reduces burning times and flaming drips, enhances mechanical and long-term stability, and allows for the reduction or elimination of halogen-containing compounds and fillers, providing excellent flame retardant properties in polyolefins while meeting or exceeding light and processing stability requirements.

Implementation Method 1

a flame-retardant article comprising a polyolefin substrate having additives incorporated therein, the additives comprising a phosphonate ester of formula (1), a synergist comprising an N-alkoxy hindered amine, and a melamine cyanurate

Methodology Applied

Scientific EffectFlame retardancy:

Implementation Method 2

required levels of light stability and processing stability can be met or exceeded

Methodology Applied

Scientific EffectThermal stability:

Implementation Method 3

required levels of light stability and processing stability can be met or exceeded

Methodology Applied

Scientific EffectLight stability:

Data Source

PatentEP3564299B1Flame retardant polyolefin articles

Publication Date: 2023.09.06 BASF SE

AI summary

The present invention relates to a flame-retardant article comprising a polyolefin substrate having additives incorporated therein, the additives comprising: a specific phosphonate ester of formula (1), a synergist comprising a specific N-alkoxy hindered amine selected from formulae (3) to (6), and a melamine cyanurate. The present invention also relates to corresponding flame retardant compositions, and the use of these for improving the flame retardency of polyolefins.