Halogen-Free Polycarbonate Blend for EV Charging Flame Retardance
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Solution Overview
Problem
There is a need for plastics that meet rigorous safety standards such as UL94 V-0, glow wire flammability, and ball pressure tests for electric vehicle charging units, while also being environmentally friendly and halogen-free, for use as wire and plug covers.
Innovation Solution
A composition comprising 10-50% polyester, 20-70% Polycarbonate A (a copolymer of 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine and bisphenol-A), 10-60% Polycarbonate B (polycarbonate/polydimethylsiloxane copolymer), and 4-10% non-halogenated flame retardants, which passes the Ball Pressure Test, Glow Wire Flammability Test, and achieves a UL94 Vertical Flame Rating of V-0.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-containing flame retardants are used to achieve UL94 V-0 rating and glow wire flammability, then flame retardance is improved, but environmental friendliness deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters by replacing halogen-containing flame retardants with non-halogenated alternatives (specifically phosphorus-based flame retardants like triphenyl phosphate and bisphenol A bis(diphenylphosphate)). This parameter change maintains the flame retardant function while eliminating the harmful environmental effects of halogens, thus resolving the contradiction between flame retardance and environmental friendliness.
Solution Approach 2:
The patent creates a composite plastic composition combining polyester (20-40 wt%), polycarbonate (30-60 wt%), and non-halogenated flame retardants (5-15 wt%). This composite material approach allows the formulation to achieve UL94 V-0 rating and glow wire flammability pass without relying on halogen-containing compounds, thereby maintaining flame safety while improving environmental compatibility.
2Reliability
If flame retardants are added to achieve fire safety standards, then flame retardance is improved, but material purity deteriorates
Solution Approach 1:
The patent optimizes the concentration parameter of flame retardants within the range of 5-15 wt%, which is sufficient to achieve UL94 V-0 rating and glow wire flammability pass while minimizing the amount of additive required. This controlled parameter adjustment balances flame retardance performance with material purity by using the minimum effective concentration of flame retardant additives.
3Object-affected harmful factors
If non-halogenated flame retardants are used to improve environmental friendliness, then environmental friendliness is improved, but flame retardance performance deteriorates
Solution Approach 1:
The patent formulates a composite material system combining polyester, polycarbonate, and non-halogenated flame retardants in specific proportions. This composite approach compensates for the potentially lower efficiency of individual non-halogenated flame retardants by creating a synergistic material system that collectively achieves UL94 V-0 rating and glow wire flammability pass, thereby maintaining flame retardance performance while improving environmental friendliness.
Solution Approach 2:
The patent selects flame retardants that serve multiple functions: non-halogenated compounds (such as phosphorus-based additives) provide both flame retardance and environmental compatibility. These multi-functional additives simultaneously address fire safety requirements and environmental concerns, resolving the contradiction between flame retardance and environmental friendliness through a single integrated solution.
Data Source
AI summary
The present invention is directed to a composition comprising: (a) 10 to 50 percent by weight of a polyethylene terephthalate (b) 20 to 70 percent by weight of Polycarbonate A, which is a copolycarbonate of 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (PPPBP) and another bisphenol; (c) 10 to 60 percent by weight of Polycarbonate B, which is a polycarbonate- polysiloxane copolymer; and (d) 4 to 10 percent by weight of a non-halogenated flame retardant provided that when the non-halogenated flame retardant is an organophosphate, organophosphonate, or organophosphonate, the weight percent is 4 to 7 percent by weight; wherein: the weight percents are based on the total weight of the composition and the composition: (i) passes the Ball Pressure Test according to (IEC) DIN EN 60695-10-2, VDE 0471 Part 10-2 or (IEC) DIN EN 60335-1 at 125 º C; or (ii) passes the Glow Wire Flammability Test (IEC) 60695-2-12 at 850 `C; and (iii) has a UL94 Vertical Flame Rating, V-0 at 1.5 mm. The invention is also directed to processes for making such compositions as well as articles derived therefrom.