Halogen-Free PP Rigid Flooring for Flame Retardancy Without Toxic Emissions
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Solution Overview
Problem
Existing PVC flooring materials pose environmental hazards due to the presence of chlorine atoms, which release toxic gases during combustion, and there is a need for environmentally friendly alternatives with comparable flame retardancy.
Innovation Solution
A halogen-free flame-retardant polypropylene (PP) rigid flooring composed of specific ratios of PP, inorganic flame retardants, toughening agents, compatibilizers, antioxidants, and lubricants, processed through twin-screw extrusion and hot-press molding, resulting in a material with high flame retardancy and environmental safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PVC flooring is used to achieve flame retardancy and dimensional stability, then flame retardancy and dimensional stability are improved, but toxic gas emission worsens
Solution Approach 1:
The patent changes the chemical composition parameters by replacing chlorine-containing PVC with halogen-free PP and inorganic flame retardants. This parameter change eliminates toxic gas emission while maintaining flame retardancy through alternative mechanisms (endothermic decomposition and free radical inhibition).
Solution Approach 2:
The patent creates a composite material system combining PP base polymer with inorganic flame retardants (aluminum hydroxide, magnesium hydroxide, red phosphorus) and functional additives. This composite structure achieves both flame retardancy and environmental safety by leveraging the non-toxic decomposition characteristics of inorganic compounds.
2Reliability
If PVC flooring is used to achieve flame retardancy, then flame retardancy is improved, but environmental friendliness worsens
Solution Approach 1:
The patent fundamentally changes the chemical composition from chlorine-based PVC to halogen-free PP system. This parameter change eliminates the formation of dioxins and hydrogen chloride during combustion, significantly improving environmental friendliness while preserving flame retardancy through inorganic flame retardant mechanisms.
Solution Approach 2:
The patent converts the traditional harmful chlorine-based flame retardancy mechanism into a beneficial halogen-free system. By using inorganic flame retardants that decompose endothermically and release water vapor, the system transforms the combustion process into a beneficial cooling and dilution effect, eliminating toxic emissions.
3Reliability
If inorganic flame retardant is added to achieve flame retardancy, then flame retardancy is improved, but mechanical properties worsen
Solution Approach 1:
The patent introduces compatibilizers as intermediary substances that bridge the inorganic flame retardant particles and the PP matrix. These compatibilizers improve interfacial adhesion and stress transfer, preventing the mechanical property degradation that would otherwise result from high inorganic filler content.
Solution Approach 2:
The patent optimizes the particle size parameter of inorganic flame retardants (1,000-5,000 mesh) and adjusts their surface treatment parameters. This parameter optimization reduces agglomeration and improves dispersion within the PP matrix, thereby maintaining mechanical properties while achieving effective flame retardancy.
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 PP flooring achieves desirable flame retardancy, environmental friendliness, and mechanical properties, with an oxygen index greater than 29% and reduced smoke density, while avoiding toxic gas emissions.
Implementation Method 1
The inorganic flame retardant has a particle size of 1,000 mesh to 5,000 mesh... 50% to 80% of the inorganic flame retardant can give the PP rigid flooring high flame retardancy
Implementation Method 2
subjecting the mixed material to twin-screw extrusion molding to obtain an extruded sheet... twin-screw extrusion at 170° C. to 230° C. and sheet molding at 200° C. to 240° C.
Implementation Method 3
subjecting the mixed material to twin-screw extrusion molding to obtain an extruded sheet
Implementation Method 4
subjecting the extruded sheet to hot-press molding and cutting to obtain the halogen-free flame-retardant PP rigid flooring... hot-press molding is conducted at 150° C. to 180° C. under 10 bar to 100 bar for 20 min to 60 min.
Implementation Method 5
hot-press molding is conducted at 150° C. to 180° C. under 10 bar to 100 bar
Data Source
AI summary
The present disclosure provides a halogen-free flame-retardant polypropylene (PP) rigid flooring and a preparation method thereof, and belongs to the technical field of flame-retardant flooring. In the present disclosure, the halogen-free flame-retardant PP rigid flooring includes the following raw materials in mass percentage: 10% to 45% of PP, 50% to 80% of an inorganic flame retardant, 1% to 15% of a toughening agent, 1% to 10% of a compatibilizer, 0.1% to 0.6% of an antioxidant, and 0.5% to 2% of a lubricant. The PP has desirable processing performance, acid and alkali resistance, chemical reagent resistance, and high- and low-temperature resistance; while a molecular structure of the PP does not contain chlorine, thus showing a high environmental protection performance. The PP as a raw material makes the PP rigid flooring exhibit light weight, high waterproof performance, desirable dimensional stability, excellent high- and low-temperature performance, and environmental friendliness.