Halogenated Epoxy Resin Formulation for Aircraft Interior Fire Safety
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Solution Overview
Problem
Epoxy resin-based prepregs for aircraft interior components lack sufficient fire retarding, low smoke emission, low smoke toxicity, and low heat release properties, while maintaining good mechanical and processing properties, which are essential for stringent safety standards.
Innovation Solution
A formulation comprising 10-80% halogenated epoxy resin, 1-15% antimony-based fire retardant, 1-10% inorganic or non-polymeric organic phosphorous containing fire retardant, and 1-30% curative system, which forms a prepreg with excellent FST and heat release properties when cured, along with improved mechanical and processing characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy resin based prepregs are used to improve surface finish and mechanical properties, then surface quality and mechanical strength are improved, but fire retarding properties and smoke emission characteristics deteriorate
Solution Approach 1:
The patent applies composite materials by combining epoxy resin with specific flame retardant additives (antimony oxide, phosphorous compounds, nitrogen-containing compounds) to create a multi-component resin system that simultaneously achieves good mechanical properties and fire safety performance. The synergistic interaction between these components resolves the contradiction between mechanical strength and fire retarding properties.
Solution Approach 2:
The patent modifies the chemical composition parameters of the epoxy resin system by incorporating specific ratios of halogenated epoxy resin (10-80%), antimony-based fire retardant (1-15%), phosphorous containing fire retardant (1-10%), and curative system (1-30%). These parameter changes enable the resin to achieve both improved mechanical properties and enhanced fire safety characteristics.
2Object-affected harmful factors
If phenolic resin based formulations are used to achieve reasonable fire retarding properties, then fire safety is improved, but surface finish quality and mechanical properties deteriorate
Solution Approach 1:
The patent changes the resin base from phenolic to epoxy resin, fundamentally altering the chemical composition parameters. This parameter change enables the system to achieve superior mechanical properties and surface finish while maintaining fire safety through the addition of flame retardant additives.
3Object-affected harmful factors
If high resin loadings and thicknesses are used to achieve excellent FST properties, then fire safety performance is improved, but processing difficulty and manufacturing complexity increase
Solution Approach 1:
The patent optimizes the chemical composition parameters of the resin system, specifically the ratios of epoxy resin to flame retardants and the selection of curative systems, to achieve excellent FST properties at manageable thicknesses. This enables good fire safety performance without requiring excessive resin loadings that would complicate processing.
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 formulation achieves excellent fire retarding, low smoke emission, low smoke toxicity, and low heat release properties, passing industry standard tests at high resin loadings and thicknesses, while maintaining superior mechanical and processing properties, such as interlaminar shear strength and flexural modulus.
Implementation Method 1
The formulation achieves excellent fire retarding, low smoke emission, low smoke toxicity, and low heat release properties
Implementation Method 2
low smoke emission, low smoke toxicity and low heat release properties
Implementation Method 3
low heat release properties, passing industry standard tests
Implementation Method 4
a curative system, which forms a prepreg with excellent FST and heat release properties when cured
Data Source
AI summary
Formulations comprising from 10 to 80% by weight of the formulation of a halogenated epoxy resin; from 1 to 15% by weight of the formulation of an antimony based fire retardant; from 1 to 10% by weight of the formulation of an inorganic or non-polymeric organic phosphorous containing fire retardant; and from 1 to 30% by weight of the formulation of a curative system are provided. The formulations are particularly suitable for producing aircraft interior composite components having good fire retarding properties, low smoke emission, low smoke toxicity and low heat release properties. The formulations also have excellent processing and mechanical properties. Further components may be included in the compositions to improve various properties, including the fire retarding, low smoke emission, low smoke toxicity and low heat release properties and to also further improve the processing and mechanical properties, including toughness. Compositions produced from the formulations have excellent processing and mechanical properties, and may also have good surface finishes.