Phosphonate Flame Retardant Styrene Resin Composition
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Solution Overview
Problem
Styrenic resins used in electrical and electronic components are prone to ignition and lack sufficient flame retardancy, necessitating the use of halogen-containing compounds that pose environmental and health risks, and existing halogen-free methods require high amounts of phosphate ester flame retardants, which can compromise resin properties.
Innovation Solution
A novel phosphonate-based compound is integrated into a styrenic resin composition, specifically a blend of styrenic resin and polyphenylene ether resin, along with a phosphorus flame retardant, to enhance flame resistance without using halogen-containing compounds, thereby improving fire stability and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-containing compounds are used as flame retardants, then flame retardancy is improved, but harmful effects on human body and environment increase
Solution Approach 1:
The patent converts the harmful halogen-containing flame retardants into beneficial phosphonate-based compounds. The phosphonate compounds provide equivalent or superior flame retardancy without releasing harmful hydrogen halide gases or toxic gases like dioxin and furan during combustion, thus converting a harmful solution into a beneficial one.
Solution Approach 2:
The patent changes the chemical composition parameter from halogen-based to phosphorus-based flame retardants. By using phosphonate compounds with specific molecular structures (where R1-R6 are specific combinations of hydrogen, alkyl, aryl, or heteroaryl groups), the flame retardancy mechanism is maintained while eliminating the harmful effects associated with halogen compounds.
2Object-affected harmful factors
If phosphate ester flame retardants are used without halogen, then harmful effects are reduced, but high amounts are required which compromise resin properties
Solution Approach 1:
The patent changes the chemical structure and concentration parameter by introducing phosphonate-based compounds with specific molecular structures. These phosphonate compounds require significantly lower concentrations compared to traditional phosphate ester flame retardants to achieve the same flame retardancy level, thereby avoiding the compromise of resin properties.
Solution Approach 2:
The patent uses composite flame retardant systems combining phosphonate-based compounds with styrenic resin and polyphenylene ether resin. This composite approach creates a synergistic effect where the phosphonate compounds work together with the resin matrix to provide enhanced flame retardancy at lower concentrations, maintaining the mechanical properties of the resin.
3Ease of operation
If rubber-modified styrenic resins are used, then processability and mechanical properties are improved, but flame retardancy is reduced due to little remaining char during combustion
Solution Approach 1:
The patent introduces phosphonate-based compounds as intermediary substances that mediate between the rubber-modified styrenic resin and the flame retardancy requirement. These phosphonate compounds promote char formation during combustion, creating a protective barrier that maintains flame retardancy while preserving the good processability and mechanical properties of the rubber-modified styrenic resin.
Solution Approach 2:
The patent creates a composite material system combining rubber-modified styrenic resin, polyphenylene ether resin, and phosphonate-based flame retardant. This composite structure leverages the processability and mechanical properties of the rubber-modified styrenic resin while the phosphonate compound provides the necessary flame retardancy through enhanced char formation, resolving the contradiction between processability and flame retardancy.
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 phosphonate-based compound achieves excellent flame resistance and impact strength in styrenic resin compositions, providing an environmentally friendly alternative to traditional halogen-based flame retardants while maintaining mechanical integrity.
Implementation Method 1
it may be necessary to add a char forming agent to a rubber-modified styrenic resin so that char can be formed in order to obtain desirable flame retardancy
Implementation Method 2
9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide is a phosphonate based cyclic compound, and a reactive flame retardant resin using the same
Data Source
Figure 1
Figure 2
AI summary
The present invention provides phosphonate compounds represented by Chemical Formula 1. In addition, the invention provides flame retardant styrene resin compositions comprising (A) styrene resin, (B) polyphenylene ether resin, and (C) the phosphonate compound. The flame retardant styrene resin compositions according to the invention: can provide protection against fire, exhibit improved strength thereof, and prevent environmental pollution by excluding halogen flame retardant agents, thereby being environment-friendly.