Methacrylic Impregnation of Fibrous Substrates

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Solution Overview

Problem

Existing methods for impregnating fibrous substrates with flame-retardant polymer matrices face challenges due to increased viscosity when adding fillers, making it difficult to achieve optimal and homogeneous impregnation, especially when using injection machines or when particle sizes of flame-retardant fillers are not optimal.

Innovation Solution

A process involving a (meth)acrylic mixture comprising a first dispersion of emulsion-polymerized (meth)acrylic polymer and a second dispersion of flame-retardant substances with particle sizes between 0.5 and 10 μm, allowing for low viscosity and effective impregnation without porosity, using a mixture of phosphorus derivative additives and hydrated mineral fillers, which adheres well to the substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If flame-retardant fillers are added to the polymer matrix, then fire resistance is improved, but viscosity increases making impregnation difficult

Engineering Contradiction:

Improvefire resistanceVSAvoidimpregnation difficulty

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent changes the particle size parameter of flame-retardant fillers to a specific range (0.5-10 μm) and adjusts the viscosity parameter of the polymer matrix to below 10,000 mPa.s, transforming the material parameters to achieve both fire resistance and ease of impregnation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite impregnation mixture containing polymer matrix, flame-retardant fillers of optimized particle size, and optionally coupling agents or lubricants, combining multiple materials to achieve synergistic effects of fire resistance, flowability, and adhesion

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If flame-retardant fillers are added to the polymer matrix, then fire resistance is improved, but impregnation homogeneity deteriorates

Engineering Contradiction:

Improvefire resistanceVSAvoidimpregnation homogeneity

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The patent optimizes the particle size parameter of fillers to 0.5-10 μm and controls viscosity below 10,000 mPa.s, ensuring uniform distribution of flame-retardant particles throughout the fibrous substrate during impregnation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent ensures that flame-retardant fillers are uniformly distributed at the local level within each region of the fibrous substrate, achieving homogeneous impregnation where each area possesses consistent fire-resistant properties

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If large particle size fillers are used, then manufacturing is simpler, but impregnation quality deteriorates with porosity

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidimpregnation quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent changes the particle size parameter from large particles to a optimized range of 0.5-10 μm, which maintains ease of handling during manufacturing while enabling complete penetration into the fibrous substrate without creating porosity

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 process ensures optimal impregnation of fibrous substrates with a homogeneous polymer matrix and adherent flame retardant, resulting in composite materials with improved mechanical and fire-resistant properties.

Implementation Method 1

During a fire, for example, the fire-retardant mixture promotes carbonization of parts, delays ignition, and minimizes degradation

Methodology Applied

Scientific EffectCarbonization: Pyrolysis

Implementation Method 2

a first dispersion comprising at least one (meth)acrylic polymer obtained by emulsion polymerization of one or more (meth)acrylic monomers

Methodology Applied

Scientific EffectEmulsion polymerization: Photopolymerisation

Data Source

PatentEP3303244B1Method for impregnating a fibrous substrate with a methacrylic mixture comprising a flame-retardant substance

Publication Date: 2022.12.14 ARKEMA FRANCE SA

AI summary

The present invention concerns a methacrylic mixture for impregnating a fibrous substrate, characterised in that it comprises: a) a first dispersion comprising at least one methacrylic polymer obtained by the emulsion polymerisation of one or more methacrylic monomers, b) a second dispersion comprising at least one flame-retardant substance. The invention also concerns a method for impregnating a fibrous substrate with such a methacrylic mixture, and a method for producing mechanical parts or structured elements or articles from the methacrylic mixture. Another object of the invention is a mechanical part or a structured element or an article made from composite material, obtained by implementing the production method.