Flame retardant mixtures, the production and the use thereof

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Solution Overview

Problem

Flame retardant mixtures based on dialkylphosphinic acids have limited thermal stability and a restricted processing window, affecting the mechanical strength and durability of flame-retardant polymer moldings, especially when exposed to moisture.

Innovation Solution

Incorporating iron into the diorganylphosphinic acid salts expands the processing window and maintains good flame retardancy, with iron present in various forms and compounds, enhancing thermal stability and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dialkylphosphinic acid salts are used as flame retardants, then flame retardancy is achieved, but thermal stability is limited and processing window is restricted

Engineering Contradiction:

Improveflame retardancyVSAvoidprocessing window

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent combines dialkylphosphinic acid salts with iron compounds to create a composite flame retardant system. This composite approach allows the mixture to maintain flame retardancy while achieving superior thermal stability and a broader processing window compared to using dialkylphosphinic acid salts alone

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical composition parameters by introducing iron compounds in specific amounts (0.01-10% by weight) to the dialkylphosphinic acid salt system. This parameter change transforms the thermal properties of the flame retardant mixture, expanding the processing temperature range from a restricted window to a broad window suitable for industrial polymer processing

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If processing temperature is increased to improve polymer transportability, then viscosity decreases and miscibility improves, but ingredient breakdown occurs

Engineering Contradiction:

Improvepolymer transportabilityVSAvoidingredient stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The iron-containing flame retardant mixture changes the thermal decomposition behavior of the system, allowing processing at higher temperatures without ingredient breakdown. The iron compounds act as thermal stabilizers that prevent decomposition up to temperatures of 200-300°C, enabling better polymer flow and mixing during compounding and injection molding

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If flame retardant mixtures are stored under moist conditions, then storage is practical, but efflorescence of breakdown products occurs

Engineering Contradiction:

Improvestorage convenienceVSAvoidchemical stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent employs iron compounds, particularly iron(II) and iron(III) salts which are readily available and cost-effective, to provide moisture resistance. These iron-based additives form stable complexes that prevent efflorescence even when the flame retardant mixture is stored under humid conditions, eliminating the need for expensive specialized stabilizers

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS11028324B2Flame retardant mixtures, the production and the use thereof

Publication Date: 2021.06.08 CLARIANT INT LTD

AI summary

The invention relates to a flame retardant mixture comprising99.9999% to 87% by weight of diorganylphosphinic acid salts as component A) and0.0001% to 13% by weight of iron as component B),where the sum total of A) and B) is 100% by weight.The invention likewise relates to processes for producing the aforementioned flame retardant mixture and to the use thereof.