Phosphorus-Capped Poly(arylene Ether) Copolymers for Flame Retardancy

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Solution Overview

Problem

Current poly(arylene ether) copolymers lack direct incorporation of phosphorus, which limits their flame retardancy and dielectric performance, and existing flame retardant additives like aromatic phosphates can act as plasticizers and migrate, reducing their effectiveness.

Innovation Solution

Development of capped poly(arylene ether) copolymers with phosphorous-containing reactive end caps that can be formed through reacting a capping agent with an uncapped poly(arylene ether) copolymer, providing improved flame retardancy and dielectric properties while being amenable to crosslinking for use in various compositions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If traditional flame retardant additives like aromatic phosphates are added to poly(arylene ether) copolymers, then flame retardancy is improved, but the additives can act as plasticizers and migrate, reducing their effectiveness and stability

Engineering Contradiction:

Improveflame retardancyVSAvoidadditive migration and plasticization

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The patent combines the flame retardant function and the polymer chain into a single integrated structure by incorporating phosphorus-containing groups directly into the poly(arylene ether) copolymer chain. This eliminates the need for separate flame retardant additives, preventing migration and plasticization while maintaining flame retardancy. The phosphorus is covalently bonded to the polymer backbone, ensuring compositional stability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The poly(arylene ether) copolymer structure itself provides flame retardancy through built-in phosphorus-containing groups, eliminating the need for external flame retardant additives. The polymer serves its own flame protection function, avoiding the problems of additive migration and plasticization that occur with traditional approaches.

Inventive Principle:

Principle #25Self-service

2Object-affected harmful factors

If capped poly(arylene ether) copolymers with phosphorous-containing end caps are synthesized, then flame retardancy and dielectric performance are improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveflame retardancyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent incorporates phosphorus-containing groups into the end caps during the polymerization process itself, rather than adding them as post-processing steps. This preliminary incorporation of flame retardant functionality into the polymer structure simplifies the overall manufacturing process by combining multiple functions into a single synthesis operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The capped poly(arylene ether) copolymer structure provides multiple functions simultaneously: the phosphorus-containing end caps provide flame retardancy, the vinyl groups enable crosslinking, and the overall structure maintains dielectric performance. This multi-functionality is achieved through a single polymer synthesis approach, avoiding the need for separate additive incorporation steps.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If poly(arylene ether) copolymers are crosslinked to improve toughness and dielectric properties, then mechanical strength and dielectric performance are enhanced, but the processing flexibility is reduced

Engineering Contradiction:

Improvetoughness and dielectric propertiesVSAvoidprocessing flexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent uses vinyl-containing end caps that allow the polymer to transition from a processable linear state to a crosslinked network state. During processing, the polymer remains linear and flexible for easy handling and molding. After processing, crosslinking occurs to provide enhanced toughness and dielectric properties. This dynamic transition between states resolves the contradiction between processing flexibility and final strength.

Inventive Principle:

Principle #15Dynamics

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 phosphorous-containing capped poly(arylene ether) copolymers offer enhanced flame retardancy, adhesion to metals, and dielectric performance, making them suitable for applications in electronics and other materials where dual functionality is required, with improved stability and performance compared to traditional flame retardant additives.

Implementation Method 1

excellent water resistance, dimensional stability, and inherent flame retardancy

Methodology Applied

Scientific EffectFlame retardancy:

Implementation Method 2

outstanding dielectric properties over wide frequency and temperature ranges

Methodology Applied

Scientific EffectDielectric properties: Dielectric

Implementation Method 3

a cured composition is obtained by heating the curable composition for a time and temperature sufficient to effect curing

Methodology Applied

Scientific EffectCuring:

Data Source

PatentEP3514195B1Dual functional poly(arylene ether) compounds

Publication Date: 2020.05.27 SABIC GLOBAL TECHNOLOGIES BV

AI summary

A capped poly(arylene ether) copolymer having the formula or wherein Y is a divalent linking group of the formula each occurrence of D is independently a group of the formula each occurrence of Z is independently of the formula and Q1a, Q1b, R1, R2, R3, R4, R5, z, x, y, e, Ra, Rb, Rc, Rd, Re, Wa, R, R', and m are as defined herein.