Halogenated Flame Retardant Resin for Transparent Fire-Resistant Glass
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Solution Overview
Problem
Current flame retardant radiation curable compositions for glass laminates are not translucent, lack impact resistance, and fail to meet stringent fire resistance tests, particularly the UL94 V0 classification, and are not suitable for making transparent fire-resistant glass for building applications.
Innovation Solution
A radiation curable flame retardant composition comprising a halogenated flame retardant, such as brominated alcohols, soluble in polymer precursors like n-butylacrylate and acrylic acid, forming a single transparent phase before curing, which is free from phosphorus and includes a combination of monomers and oligomers with (meth)acryl groups, along with a photochemical initiator, to create a transparent, impact-resistant, and fire-resistant glass laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphorous containing compositions are used for flame retardancy, then flame retardant properties are improved, but translucency is lost and UL94 V0 classification cannot be achieved
Solution Approach 1:
The patent changes the chemical composition parameters by using halogenated flame retardants (specifically brominated compounds) instead of phosphorous-containing compositions. This parameter change maintains flame retardant properties while achieving translucency and UL94 V0 classification, as the halogenated compounds do not interfere with light transmission in the cured resin.
Solution Approach 2:
The patent employs a clear/transparent resin system that is designed to be optically invisible once cured, allowing the flame retardant properties to be achieved without compromising translucency. The use of halogenated flame retardants in specific concentrations (5-50 wt%) allows achieving UL94 V0 classification while maintaining optical clarity.
2Temperature
If ceramic glasses are used for fire resistance, then fire resistance at high temperatures is improved, but impact resistance is reduced
Solution Approach 1:
The patent creates a composite laminate structure combining glass panes with a cured radiation-curable resin interlayer containing halogenated flame retardants. This composite approach achieves fire resistance (surviving temperatures in excess of 900°C) while maintaining impact resistance, as the resin interlayer provides toughness and flexibility that ceramic glasses lack.
Solution Approach 2:
The patent applies different materials to different parts of the glazing system: glass panes for structural integrity and fire resistance, and a resin interlayer containing halogenated flame retardants for impact resistance and additional flame retardancy. This local differentiation of material properties allows the overall system to achieve both fire resistance and impact resistance simultaneously.
3Temperature
If thermoplastic fluorinated films are used for lamination, then fire resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical lamination process using thermoplastic fluorinated films with a radiation-curing chemical process. The radiation-curable composition containing halogenated flame retardants cures in place to form the interlayer, eliminating the need for specialized lamination equipment and complex manufacturing processes while achieving equivalent or superior fire resistance.
Solution Approach 2:
The patent changes the processing parameters from thermal-mechanical lamination (requiring heat and pressure equipment) to photopolymerization or electron beam curing. This parameter change simplifies manufacturing by using radiation curing at ambient or elevated temperatures without requiring complex lamination equipment, while the halogenated flame retardants ensure fire resistance is achieved.
4Ease of manufacture
If standard glass is used for glazing, then manufacturing simplicity is maintained, but fire resistance is insufficient
Solution Approach 1:
The patent creates a composite glass laminate where standard glass panes are bonded with a radiation-curable resin interlayer containing halogenated flame retardants. This composite structure maintains the manufacturing simplicity of using standard glass while achieving fire resistance (surviving temperatures in excess of 900°C) that standard glass alone cannot provide.
Solution Approach 2:
The radiation-curable resin interlayer containing halogenated flame retardants acts as an intermediary between standard glass panes, providing the fire resistance property that standard glass lacks. This intermediary layer allows standard glass to be used while achieving the required fire resistance through the flame retardant properties of the cured resin.
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 achieves high impact resistance, acoustic insulation, and meets the UL94 V0 classification, enabling the production of transparent, fire-resistant glass laminates with improved safety and performance, suitable for various applications including fire-resistant glazing.
Implementation Method 1
The UV radiation activates the reactive monomers of the system through the photoinitiator and starts the polymerization
Implementation Method 2
at least one halogenated flame retardant which is soluble in said composition
Data Source
AI summary
The invention relates to a flame retardant composition comprising at least one radiation curable polymer precursor and at least one halogenated flame retardant which is soluble in the composition and their use to make fire resistant glass laminates.