Melamine Polyphosphate Flame Retardant Composition
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Solution Overview
Problem
Polyphosphate salts used in intumescent flame retardants can produce strongly acidic salts during production, leading to poor heat resistance and potential corrosion of processing machines, and may affect the weather resistance of synthetic resin compositions.
Innovation Solution
A method for preparing a flame-retardant synthetic resin composition using melamine pyrophosphate or melamine polyphosphate, which are produced through a heating condensation reaction of melamine orthophosphate, along with piperazine pyrophosphate and a hydrotalcite compound, to enhance heat and weather resistance while minimizing corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyphosphate salts are used as flame retardants, then flame retardancy is improved, but heat resistance deteriorates due to strong acidity
Solution Approach 1:
A water-soluble organic acid is introduced as an intermediary substance to react with the polyphosphate salt and neutralize its strong acidity. This mediator allows the flame retardant to maintain its flame-retardant properties while reducing the harmful acidic effects that compromise heat resistance.
Solution Approach 2:
The chemical parameters of the flame retardant system are modified by changing the pH level through neutralization reactions. By adjusting the acidity parameter of the polyphosphate salt using water-soluble organic acids, the system achieves a balance between maintaining flame retardancy and improving heat resistance.
2Reliability
If polyphosphate salts are used as flame retardants, then flame retardancy is improved, but processing machines may be corroded due to strong acidity
Solution Approach 1:
Water-soluble organic acids serve as intermediaries that neutralize the strong acidity of polyphosphate salts. This reduces the corrosive impact on processing machines during compounding while preserving the flame-retardant functionality of the polyphosphate salt.
Solution Approach 2:
The strong acidity of polyphosphate salts, which causes corrosion, is converted into a beneficial neutralization reaction with water-soluble organic acids. The harmful acidic property is transformed into a controlled chemical reaction that eliminates corrosion while maintaining flame retardancy.
3Reliability
If polyphosphate salts are used as flame retardants, then flame retardancy is improved, but weather resistance of synthetic resin composition deteriorates
Solution Approach 1:
Water-soluble organic acids are used as intermediaries to modulate the chemical environment of the polyphosphate salt. This neutralization reduces the adverse chemical interactions that would otherwise compromise the weather resistance of the synthetic resin composition containing the flame retardant.
4Reliability
If halogen-based flame retardants are used, then flame retardancy is improved, but hazardous gases are generated on combustion
Solution Approach 1:
The harmful halogen component is extracted or removed from the flame retardant system. The invention replaces halogen-based flame retardants with polyphosphate salts combined with water-soluble organic acids, eliminating the source of hazardous combustion gases while maintaining effective flame retardancy.
Solution Approach 2:
The invention converts from a harmful halogen-based system to a beneficial non-halogen system. By using polyphosphate salts with water-soluble organic acids, the flame retardant achieves effective flame suppression without generating toxic combustion products, transforming a harmful approach into a safe one.
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 method results in a flame-retardant composition with excellent heat resistance, reduced risk of machine corrosion, and improved weather resistance for the synthetic resin composition, producing a shaped product with enhanced flame retardancy and durability.
Implementation Method 1
melamine pyrophosphate or melamine polyphosphate, which are produced through a heating condensation reaction of melamine orthophosphate
Implementation Method 2
intumescent flame retardants--i.e., flame retardants that include a polyphosphate salt as a main component and that form a surface-swelling (intumescent) layer on combustion, thus achieving flame retardancy by preventing the diffusion of decomposition products and the transfer of heat
Data Source
AI summary
The invention provides a flame retardant composition that has excellent heat resistance and in which the risk of corroding processing machines at the time of compounding resin is reduced. Specifically, the invention provides a flame retardant composition comprising 20 to 50 parts by mass of component (A) described below, 50 to 80 parts by mass of component (B) described below (the total of the component (A) and the component (B) is 100 parts by mass), and 0.01 to 5 parts by mass of component (C) described below: component (A): at least one type of melamine salt selected from melamine orthophosphate, melamine pyrophosphate, melamine polyphosphate, or a mixture including two or more types of the melamine salts; component (B): at least one type of piperazine salt selected from piperazine orthophosphate, piperazine pyrophosphate, piperazine polyphosphate, or a mixture including two or more types of the piperazine salts; and component (C): a hydrotalcite compound.