Phosphorus Epoxy Flame Retardant Tg Trade-off

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Solution Overview

Problem

Current phosphorus-containing flame retardants for epoxy resins are either insufficient in flame retardancy, adversely affect the curing process, or reduce the glass transition temperature of the cured product, while bromine-containing flame retardants generate toxic gases upon combustion.

Innovation Solution

A phosphorus-containing compound with a specific structure that reacts with epoxy compounds to form a curing epoxy resin composition, providing excellent reactivity, flame retardation, and reduced dielectric constant without compromising physical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a phosphorus-containing flame retardant is added to epoxy resin to achieve flame retardancy, then flame retardant effect is improved, but glass transition temperature is reduced and physical properties are adversely affected

Engineering Contradiction:

Improveflame retardancyVSAvoidglass transition temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent changes the chemical structure parameters of the phosphorus-containing compound by introducing specific groups (aryl, alkyl, alkanediyl, alkanetriyl, alkanetetrayl) and controlling the number of epoxy-reactive groups (m=1-10) to optimize both flame retardancy and glass transition temperature. This structural parameter optimization allows achieving flame retardancy without excessive reduction in Tg

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite curing agent system by combining the phosphorus-containing compound with epoxy resin, forming a new material system that integrates flame retardant properties with the epoxy matrix while maintaining structural integrity and physical properties of the cured product

Inventive Principle:

Principle #40Composite materials

2Reliability

If a large amount of flame retardant is added to achieve sufficient flame retardancy, then flame retardant effect is improved, but glass transition temperature is reduced

Engineering Contradiction:

Improveflame retardancyVSAvoidglass transition temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent optimizes the chemical structure of the phosphorus-containing compound to enhance its flame retardant efficiency per unit mass. By designing specific molecular structures with controlled epoxy-reactive groups, the flame retardant achieves satisfactory flame retardancy at lower addition amounts, thereby minimizing the negative impact on glass transition temperature

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a reactive phosphoric ester compound is incorporated into epoxy resin to improve flame retardancy, then flame retardant effect is improved, but viscosity increases and workability is greatly reduced

Engineering Contradiction:

Improveflame retardancyVSAvoidworkability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent modifies the structural parameters of the phosphoric ester compound by introducing specific aryl, alkyl, and alkanediyl groups, which control the molecular size and intermolecular interactions. This structural optimization reduces excessive viscosity increase while maintaining the reactive phosphorus functionality needed for flame retardancy and epoxy curing

Inventive Principle:

Principle #35Parameter changes

4Reliability

If a phosphorus-containing flame retardant is used to achieve flame retardancy, then flame retardant effect is improved, but harmful gas generation is not sufficiently reduced

Engineering Contradiction:

Improveflame retardancyVSAvoidtoxic gas generation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the potential harm of phosphorus-containing compounds (which may produce harmful gases upon combustion) into a beneficial outcome by designing specific molecular structures that promote formation of protective char layers during combustion. This char layer acts as a barrier that prevents release of toxic gases, thereby converting a potentially harmful combustion behavior into a protective mechanism that reduces harmful gas generation

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 phosphorus-containing compound effectively imparts flame retardancy and reduces the dielectric constant of the epoxy resin while maintaining the physical properties of the cured product, offering a safer and more environmentally friendly alternative.

Implementation Method 1

a phosphorus-containing compound having reactivity with a glycidyl group... capable of providing a curing epoxy resin composition

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS9738667B2Phosphorus-containing compound and curing epoxy resin composition containing same

Publication Date: 2017.08.22 ADEKA CORP

AI summary

Provided is a novel phosphorus-containing compound represented by general formula (I). The compound has reactivity with a glycidyl group and is therefore capable of providing a curing epoxy resin composition that is expected to achieve flame retardation and reduction of dielectric constant.wherein m is a number of 1 to 10; R1, R2, R3, and R4 are each hydrogen, alkyl, or aryl; R5 is alkyl, alkanediyl, alkanetriyl, alkanetetrayl, or an aromatic group; X is oxygen or sulfur; Y is oxygen, sulfur, or ═NR′; and R′ is hydrogen, alkyl, or aryl.