Flame Retardant Polymer Composition Using Maleic Anhydride Coupling Agent
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Solution Overview
Problem
Existing flame retardant polymer compositions face challenges in achieving a balance between good flame retardancy, processability, mechanical properties, and cost-effectiveness, particularly in passing the FIPEC test while maintaining extrudability and tensile strength, and often suffer from the use of halogen- and phosphorous-containing compounds or high amounts of inorganic fillers that deteriorate mechanical properties.
Innovation Solution
Incorporating an ethylene copolymer with at least 0.6 wt.% maleic anhydride units as a coupling agent in a flame retardant polymer composition that includes uncoated aluminum hydroxide as the filler material, enhancing compatibility and distribution within the composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-containing compounds are used as flame retardants, then flame retardancy is improved, but hazardous and corrosive gases are released upon burning
Solution Approach 1:
The patent replaces halogen-containing compounds with hydrogen-containing inorganic fillers (Al(OH)3, Mg(OH)2) that release harmless water vapor instead of hazardous gases when decomposed during burning, converting a harmful flame retardant approach into a benign one while maintaining flame retardancy through endothermic decomposition
Solution Approach 2:
The patent changes the chemical composition parameter from halogen-based to hydrogen-based flame retardants, and optimizes the filler content parameter to 40-60 wt.% to achieve effective flame retardancy without excessive filler that would deteriorate mechanical properties
2Reliability
If high amounts of inorganic fillers (50-60 wt. %) are used to improve flame retardancy, then flame retardancy is improved, but processability and mechanical properties deteriorate
Solution Approach 1:
The patent introduces silane-modified polymers as intermediary coupling agents between inorganic fillers and polymer matrix, improving interfacial adhesion and compatibility, which allows high filler content (40-60 wt.%) to be used without severe deterioration of processability and mechanical properties
Solution Approach 2:
The patent creates a composite material system combining inorganic fillers (Al(OH)3, Mg(OH)2) with silane-modified polymers, where the silane modification provides both flame retardancy enhancement and improved interfacial bonding, resolving the contradiction between filler content and mechanical properties
3Reliability
If high amounts of inorganic fillers (50-60 wt. %) are used to improve flame retardancy, then flame retardancy is improved, but mechanical properties deteriorate
Solution Approach 1:
The silane-modified polymer acts as a mediator that strengthens the interface between inorganic fillers and the polymer matrix through chemical bonding, preventing filler aggregation and maintaining mechanical integrity even at high filler loadings of 40-60 wt.%, thus preserving tensile strength and elongation properties
Solution Approach 2:
The silane-modified composite structure creates a synergistic effect where the modified polymer matrix and inorganic fillers work together to maintain mechanical properties while achieving high flame retardancy, avoiding the mechanical property deterioration typical of simple filler composites
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 solution achieves improved flame retardancy, meeting class D, C, or B2 requirements of the FIPEC test, while maintaining good mechanical properties and processability, and is cost-effective, with reduced or no halogen- and phosphorous-containing compounds, thus overcoming the limitations of prior art.
Implementation Method 1
The polar maleic anhydride units in the ethylene copolymer assure the compatibility between the polymer base resin and the uncoated inorganic filler material and thus improve the distribution of the latter in the final composition
Implementation Method 2
hydrated and hydroxy compounds, which during burning decompose endothermically and deliberate inert gases at temperatures in the range of 200 to 600° C. Such inorganic fillers e.g. include Al(OH)3 and Mg(OH)2
Data Source
AI summary
The present invention relates to a flame retardant polymer composition comprising (A) an ethylene copolymer comprising alkyl acrylate comonomer units, (B) uncoated aluminum hydroxide as inorganic filler, and (C) an ethylene copolymer comprising maleic anhydride units in an amount of 0.6 to 5 wt. %, an article comprising such a composition, the use of such a composition for producing a layer in a wire or cable and the use of an ethylene copolymer comprising maleic anhydride units for producing a wire or cable fulfilling the requirements of class D of the FIPEC test according to prEN 50399:2007./.