Non-dripping Flame Retardant Masterbatch via Crosslinking
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Solution Overview
Problem
Current flame retarding materials for textiles face issues such as poor processability, mechanical properties, and unsatisfactory flame retarding efficacy, often resulting in dripping during combustion, and high production costs due to high flame retardant content.
Innovation Solution
A non-dripping flame retarding masterbatch composition comprising 0.1-15 wt% flame retardant, 0.1-1.5 wt% crosslinking agent, 76.5-99.5 wt% thermoplastic polymer, and 0.01-2.0 wt% crosslinking initiator, which is compounded and pelletized to achieve adequate flame retarding capability with reduced flame retardant content, improving spinnability and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high content of phosphorus-containing flame retardants (e.g., polyphosphate, ammonium polyphosphate) is used to achieve satisfactory flame retarding efficacy, then flame retarding efficacy is improved, but manufacturing cost increases and spinnability decreases
Solution Approach 1:
The patent changes the chemical composition parameters by introducing crosslinking agents and crosslinking initiators to modify the physical and chemical properties of the flame retarding material. This enables achieving satisfactory flame retarding efficacy at lower flame retardant contents (5-20 wt%), thereby improving spinnability and reducing manufacturing cost while maintaining reliability
Solution Approach 2:
The patent creates a composite material system combining flame retardants with crosslinking agents and crosslinking initiators. This composite approach allows the flame retardant to form a crosslinked network structure that enhances flame resistance without requiring high concentrations, thus resolving the contradiction between flame retarding efficacy and spinnability
2Reliability
If phosphorus-containing flame retardants are used to achieve flame retarding efficacy, then flame retarding efficacy is improved, but dripping effect occurs during combustion
Solution Approach 1:
The patent modifies the physical state and thermal properties of the flame retarding material through crosslinking. The crosslinked network structure prevents melting and dripping during combustion while maintaining flame retarding efficacy, thus eliminating the harmful dripping effect
Solution Approach 2:
The patent converts the potential harm of phosphorus-containing flame retardants (dripping) into a benefit by using crosslinking to create a thermally stable network structure. This crosslinked structure prevents dripping while preserving the flame retarding properties, turning a harmful characteristic into a beneficial non-dripping property
3Object-generated harmful factors
If inorganic flame retardants (e.g., antimony trioxide, magnesium hydroxide, aluminium hydroxide) are used to produce less smoke, then smoke reduction is improved, but flame retarding efficacy is insufficient and compatibility with thermoplastic materials is poor
Solution Approach 1:
The patent uses crosslinking agents and crosslinking initiators as intermediary substances that facilitate the formation of a crosslinked network. This network structure improves the compatibility and dispersion of inorganic flame retardants within thermoplastic materials, enhancing both flame retarding efficacy and smoke reduction properties
Solution Approach 2:
The patent creates a composite system combining inorganic flame retardants with crosslinking agents. This composite approach allows inorganic materials to form a stable crosslinked network that improves their compatibility with thermoplastic materials and enhances flame retarding efficacy while maintaining low smoke production
4Reliability
If red phosphorus is used to achieve high flame retarding efficacy (up to 100% phosphorus content), then flame retarding efficacy is improved, but appearance and compatibility with plastic materials deteriorate
Solution Approach 1:
The patent uses crosslinking agents and crosslinking initiators as temporary additives that facilitate the formation of a crosslinked network during processing. These crosslinking components are consumed during the crosslinking reaction and are not present in the final product, allowing the use of highly effective but difficult-to-process red phosphorus as the flame retardant
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 provides a non-dripping flame retarding material with enhanced flame retarding efficacy, reduced production costs, and improved spinnability, as evidenced by higher Limited Oxygen Index (LOI) values and non-dripping performance in combustion tests, while maintaining mechanical properties.
Implementation Method 1
The composition is compounded to melt the thermoplastic polymer whereby the melted thermoplastic polymer is cross-linked by the crosslinking agent
Implementation Method 2
about 0.01 to about 2.0 wt % crosslinking initiator was added into the admixture to form a composition for compounding
Implementation Method 3
the retarding agent is dispersed in the cross-linked thermoplastic
Data Source
AI summary
Disclosed herein is a composition for preparing a non-dripping flame retarding masterbatch. The flame retarding masterbatch includes a fire retardant in an amount of about 0.1-15.0 wt %, a crosslinking agent in an amount of about 0.1-1.5 wt %, a thermoplastic polymer in an amount of about 76.5-99.5 wt %, a crosslinking initiator in an amount of about 0.01-2.0 wt %, and a dispersing agent in an amount of about 0.1-5.0 wt % in the composition.