Melamine Cyanurate Prepreg for Thin Flame-Retardant Composites

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Solution Overview

Problem

Conventional fiber-reinforced composite materials face challenges in achieving both thinness and flame retardancy, especially when thickness is small, due to the use of halogenated and phosphorus-based flame retardants, which generate toxic gases and pose environmental concerns during disposal.

Innovation Solution

A prepreg comprising carbon fibers and a resin composition with an epoxy resin having a biphenyl structure, a curing agent, and melamine cyanurate, which allows for the formation of a fiber-reinforced composite material that achieves thinness and flame retardancy without using halogenated or phosphorus-based flame retardants, with specific mass content ratios and low chlorine and phosphorus levels to ensure environmental safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogenated flame retardant or phosphorus-based flame retardant is used to achieve flame retardancy, then flame retardancy is improved, but toxic gas is generated during combustion and environmental load increases during disposal

Engineering Contradiction:

Improveflame retardancyVSAvoidtoxic gas generation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the flame retardant system by using melamine cyanurate (20-40% by mass) combined with epoxy resin having a biphenyl structure, replacing conventional halogenated and phosphorus-based flame retardants. This parameter change achieves flame retardancy (V-0 or V-1 rating) while eliminating toxic gas generation during combustion.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite resin system combining melamine cyanurate with epoxy resin having a biphenyl structure and a curing agent. This composite material approach provides synergistic flame retardant properties while maintaining mechanical strength and avoiding the harmful effects of conventional flame retardants.

Inventive Principle:

Principle #40Composite materials

2Length of moving object

If the thickness of fiber-reinforced composite material is reduced to achieve thinness, then weight and housing thickness are reduced, but sufficient flame retardancy becomes difficult to secure

Engineering Contradiction:

ImprovethicknessVSAvoidflame retardancy

Core Design Contradiction:

Length of moving objectVSReliability

Solution Approach 1:

The patent changes the flame retardant mechanism by incorporating melamine cyanurate in a specific concentration (20-40% by mass of resin composition), which provides sufficient flame retardancy even in thin materials (1.5 mm or less thickness) without requiring increased thickness for compensation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts and eliminates harmful flame retardant chemicals (halogenated and phosphorus-based compounds) while retaining the essential flame retardancy function through the use of melamine cyanurate, enabling thin design without sacrificing safety performance.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If melamine cyanurate content is increased to improve flame retardancy, then flame retardancy is improved, but the complexity of resin composition formulation increases

Engineering Contradiction:

Improveflame retardancyVSAvoidresin composition formulation

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent optimizes the formulation parameters by specifying melamine cyanurate content within a defined range (20-40% by mass of resin composition) and controlling chlorine and phosphorus content at low levels (≤1% and ≤0.1% by mass respectively). This parameter optimization achieves flame retardancy while maintaining formulation simplicity and manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

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 enables the production of a fiber-reinforced composite material with V-0 or V-1 flame retardancy ratings, as evaluated by the UL94 burning test, while maintaining thinness and ensuring environmental safety by eliminating toxic gas generation during combustion.

Implementation Method 1

a fiber-reinforced composite material that achieves both thinness and flame retardancy

Methodology Applied

Scientific EffectFlame retardancy:

Implementation Method 2

melamine cyanurate...without using the halogenated flame retardant and phosphorus-based flame retardant

Methodology Applied

Scientific EffectChar formation:

Implementation Method 3

resin composition containing an epoxy resin having a biphenyl structure, a curing agent

Methodology Applied

Scientific EffectEpoxy curing:

Implementation Method 4

fiber-reinforced composite material consisting of carbon fibers and a matrix resin

Methodology Applied

Scientific EffectFiber reinforcement:

Data Source

PatentUS11319406B2Prepreg, fiber-reinforced composite material, and molded article

Publication Date: 2022.05.03 ENEOS MATERIALS CORP

AI summary

A prepreg comprising: carbon fibers; and a resin composition containing an epoxy resin having a biphenyl structure, a curing agent, and melamine cyanurate.