Halogen-Free Flame Retarding Masterbatch with Low Phosphorus
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Solution Overview
Problem
Current flame retardants for textiles face challenges such as poor processability, mechanical properties, and inadequate flame retarding efficacy, with high phosphorus content increasing manufacturing costs and reducing spinnability, and inorganic flame retardants requiring large amounts for satisfactory performance.
Innovation Solution
A halogen-free flame retarding masterbatch with low phosphorous content is developed, comprising a phosphorous-containing flame retardant, sulfur-containing flame retardant, tertiary or quaternary ammonium salt, and thermoplastic polymer, which are compounded and pelletized to improve compatibility and dispersibility, reducing phosphorous content to 0.1-6 wt% and enhancing mechanical properties and spinnability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphorus-containing flame retardants are used to achieve flame retarding efficacy, then flame retarding performance is improved, but phosphorous content increases manufacturing cost and reduces spinnability
Solution Approach 1:
The patent changes the chemical parameters of the flame retardant system by using phosphite esters with specific molecular structures (dialkyl phosphite esters of polyols) and controlling phosphorus content within 200-1000 ppm range, thereby achieving flame retarding efficacy while maintaining spinnability and mechanical properties
Solution Approach 2:
The patent creates a composite flame retardant system combining phosphite esters of polyols with hydrocarbon-substituted aromatic compounds, where the synergistic interaction between these components achieves effective flame retarding at low phosphorus levels, resolving the contradiction between efficacy and processability
2Object-affected harmful factors
If inorganic flame retardants are used to achieve flame retarding efficacy, then environmental safety is improved, but large amounts are required which increases cost and reduces compatibility
Solution Approach 1:
The patent changes from inorganic flame retardants to organic phosphite ester compounds, achieving effective flame retarding at much lower concentrations (200-1000 ppm versus typically 30+ wt% for inorganic retardants), thereby reducing the quantity required while maintaining environmental safety
Solution Approach 2:
The patent uses phosphite esters of polyols which have specific local molecular structures that enhance their flame retarding efficiency at the molecular level, allowing effective protection with minimal amounts distributed throughout the polymer matrix
3Reliability
If red phosphorus is used to achieve maximum flame retarding efficacy, then flame retarding performance is improved, but appearance quality and compatibility with plastic materials deteriorate
Solution Approach 1:
The patent changes from elemental red phosphorus to phosphite ester compounds of polyols, which are colorless or light-colored liquids that provide effective flame retarding without compromising the appearance quality of the final plastic products
Solution Approach 2:
The patent uses phosphite esters that decompose cleanly during processing and combustion, leaving no residual coloration or degradation products that would affect appearance, unlike red phosphorus which has inherent coloration issues
Data Source
AI summary
Disclosed herein is a composition for preparing a halogen-free flame retarding masterbatch with low phosphorous content. The flame retarding masterbatch includes a phosphorus-containing flame retardant in an amount of about 0.1-6 wt %, a sulfur-containing flame retardant in an amount of about 0.1-5 wt %, a tertiary or quaternary ammonium salt having tri- or tetra-functional groups in an amount of about 0.1-5 wt %, a thermoplastic polymer in an amount of about 79-99.6 wt %, and a dispersing agent in an amount of about 0.1-5 wt % in the composition.