Insulating Resin Molded Article Flame Retardance Stabilization

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Solution Overview

Problem

Conventional insulating resin molded articles for electrical components face challenges in simultaneously achieving excellent flame retardance, mechanical properties, water resistance, dimensional stability, and impact resistance, especially when exposed to heat aging, and are limited in size reduction and color variability due to the use of halogen-based and phosphorous-based flame retardants.

Innovation Solution

A thermoplastic resin composition comprising a polyphenylene ether-based resin, a hydrogenated block copolymer, a phosphoric acid-based flame retardant, and titanium oxide, which maintains stable flame retardance and balances tracking resistance and impact resistance, even after heat aging, while allowing for a reduced component size and various color options.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogen-based flame retardants are used to achieve excellent flame retardance, then flame retardance is improved, but environmental safety requirements are not satisfied and component size reduction is limited

Engineering Contradiction:

Improveflame retardanceVSAvoidenvironmental safety compliance

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the chemical composition parameters by replacing halogen-based flame retardants with phosphoric acid-based flame retardants in specific quantity ranges (5-20 parts by mass based on 100 parts of polyphenylene ether resin). This parameter change achieves compliance with environmental safety requirements while maintaining flame retardance through the chemical properties of phosphoric acid-based compounds.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining polyphenylene ether resin with phosphoric acid-based flame retardant and titanium oxide. This composite formulation achieves synergistic effects where the flame retardant and pigment work together to provide both flame retardance and color variability without requiring halogen-based compounds, thus satisfying environmental requirements.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If phosphorous-based flame retardants are used to meet environmental requirements, then environmental safety is improved, but flame retardance after heat ageing deteriorates

Engineering Contradiction:

Improveenvironmental safety complianceVSAvoidflame retardance after heat ageing

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent introduces titanium oxide as an intermediary substance that stabilizes the flame retardant's performance after heat ageing. The titanium oxide particles interact with the phosphoric acid-based flame retardant to prevent degradation, maintaining flame retardance even after exposure to high temperatures during ageing processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The composite material system combines phosphoric acid-based flame retardant with titanium oxide in specific proportions. This composite structure protects the flame retardant properties from heat degradation, as the titanium oxide acts as a stabilizing matrix that preserves the flame retardant's effectiveness after ageing.

Inventive Principle:

Principle #40Composite materials

3Productivity

If component size is reduced for downsizing, then productivity and adaptability are improved, but tracking resistance and insulation distance are compromised

Engineering Contradiction:

Improvecomponent downsizing capabilityVSAvoidtracking resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the material's electrical and surface properties through the addition of phosphoric acid-based flame retardant and titanium oxide. These compositional changes increase the material's tracking resistance and electrical insulation properties, allowing shorter creepage distances to be used safely, thus enabling component downsizing without compromising electrical safety.

Inventive Principle:

Principle #35Parameter changes

4Strength

If impact resistance is improved by adding rubber modifiers, then mechanical properties are improved, but flame retardance and dimensional stability deteriorate

Engineering Contradiction:

Improveimpact resistanceVSAvoidflame retardance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent achieves impact resistance through compositional parameters rather than rubber modification. By optimizing the content of phosphoric acid-based flame retardant (5-20 parts) and titanium oxide (0.1-5 parts) per 100 parts of polyphenylene ether resin, the material attains both high impact resistance and maintained flame retardance, avoiding the need for rubber additives that would compromise flame properties.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9991622B2Electrical component comprising insulating resin molded article, and method for stabilizing flame retardance

Publication Date: 2018.06.05 ASAHI KASEI CHEM CORP

AI summary

Provided is an electric component equipped with a live electrical part and an insulating resin molded article that is molded from a thermoplastic resin composition and is in contact with the live electrical part, wherein: the thermoplastic resin composition includes (A) 60 to 80 parts by mass of a polyphenylene ether resin or a mixture of a polyphenylene ether resin and a styrene resin, (B) 60 to 80 parts by mass of a hydrogenated block copolymer, (C) 5 to 30 parts by mass of a flame retardant, and (D) 0.1 to 3 parts by mass of titanium oxide (in an amount corresponding to 100 parts by mass of the total of (A) to (C)).