PC/ABS Composite Flame Retardancy via Phosphorus Char Formation
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Solution Overview
Problem
Inorganic flame retardants require high amounts to achieve desired fire-proof effects in composite materials, increasing costs and compromising mechanical properties, while halogen-based alternatives are being phased out due to environmental concerns.
Innovation Solution
A flame retarding composite material is developed using a phosphorus-containing flame retardant with a P═X double bond in a PC/ABS composite material, combined with glass fibers to enhance mechanical strength and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic flame retardant is used to achieve flame retardancy, then fire-proof property is improved, but mechanical properties deteriorate and production cost increases
Solution Approach 1:
The patent changes the chemical composition parameter of the flame retardant from inorganic to phosphorus-containing organic compound with P═X double bond, achieving both flame retardancy and maintained mechanical properties through molecular-level chemical interaction with the polymer matrix
Solution Approach 2:
The patent creates a composite flame retardant system combining phosphorus-containing compound with P═X double bond and glass fiber reinforcement, where the phosphorus compound provides flame retardancy through char formation while glass fiber maintains mechanical strength
2Reliability
If inorganic flame retardant is used to achieve flame retardancy, then fire-proof property is improved, but production cost increases
Solution Approach 1:
The patent changes the flame retardant chemistry from inorganic to phosphorus-containing organic compounds, enabling effective flame protection at lower loading levels (1-5 wt% P) compared to inorganic alternatives, thus reducing material cost and processing complexity
Solution Approach 2:
The patent concentrates flame retardant functionality in specific phosphorus-containing compounds with P═X double bonds that form protective char layers locally at the combustion interface, providing efficient flame protection with minimal additive quantity
3Reliability
If halogen-containing material is used for flame retarding, then flame retardancy is achieved, but environmental compatibility worsens
Solution Approach 1:
The patent converts the traditionally harmful halogen-based flame retardancy mechanism into a beneficial phosphorus-based char formation process, where the P═X double bond compounds decompose to form protective phosphoric acid and char layers that suppress combustion without releasing toxic halogen gases
Solution Approach 2:
The patent changes the chemical element basis of the flame retardant from halogen (Cl, Br) to phosphorus, fundamentally altering the decomposition products from toxic halogenated dioxins and furans to benign phosphoric acid and carbonaceous char, achieving environmentally compatible flame protection
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 improved heat resistance and flame retardancy with a lower amount of phosphorus, meeting UL-94 V0 specifications while maintaining mechanical properties and reducing production costs.
Implementation Method 1
the polyphosphoric acid will react with oxygen (O) or hydroxyl (OH) in the composite material when heating, so that the plastic material is esterified dehydration to form a carbon layer which provides fireproof/flame retardant effect
Implementation Method 2
the plastic material is esterified dehydration to form a carbon layer when heating
Implementation Method 3
the above glass fiber can effectively enhance the mechanic strength and aging resistance
Data Source
AI summary
A flame retarding composite material includes at least a PC resin, an ABS resin, a flame retardant having a P═X double bond, and an additive. The PC resin in the composite material is in the range of 60 wt % to 80 wt %. The ABS resin in the composite material is in the range of 15 wt % to 35 wt %. The additive can includes 5 wt % to 37 wt % of glass fiber.