Phosphorus Flame Retardant for Thermoplastic Resins
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Solution Overview
Problem
Conventional halogen-based and antimony-based flame retardants used in thermoplastic polyester resins generate toxic gases during fires and require excessive amounts to achieve desired flame retardancy, which can degrade the physical properties of the resin.
Innovation Solution
A novel phosphorus (P)-based flame retardant, represented by Chemical Formulas 1 and 2, is introduced, which can provide excellent flame retardancy even at reduced amounts compared to conventional flame retardants, while maintaining or improving the mechanical properties of the thermoplastic resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-based or antimony-based flame retardants are used to achieve flame retardancy in thermoplastic polyester resins, then flame retardant effect is improved, but toxic gas generation increases and physical properties of the resin are degraded
Solution Approach 1:
The patent changes the chemical composition parameters by introducing a novel phosphorus-based flame retardant with specific molecular structure (Formula 1) containing P-O-C bonds and specific functional groups, replacing conventional halogen-based or antimony-based flame retardants. This parameter change achieves flame retardancy while eliminating toxic gas generation and reducing usage amount to 1-30 parts by weight per 100 parts resin, thereby preserving physical properties
Solution Approach 2:
The patent creates a composite flame retardant system by combining phosphorus-based compounds with specific metal elements (Al, Si, Ti, Zr, Sn, Zn, Mn, Fe, Co, Ni, Cu, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu) in defined ratios. This composite approach enhances flame retardant efficiency, allowing reduced usage amounts while maintaining or improving mechanical properties such as tensile strength and impact strength
2Reliability
If excessive amount of flame retardant is used to achieve desired flame retarding effects, then flame retardancy is improved, but mechanical properties of the resin are excessively degraded
Solution Approach 1:
The patent optimizes the concentration parameter of the flame retardant to 1-30 parts by weight per 100 parts resin, which is significantly lower than conventional flame retardants. This parameter optimization, combined with the improved molecular structure efficiency, achieves desired flame retardancy (UL94 V-0 rating) while minimizing degradation of mechanical properties such as tensile strength and impact strength
Solution Approach 2:
The patent employs composite phosphorus-based flame retardants with metal elements that enhance flame retardant efficiency at lower concentrations. The synergistic effect of the composite structure allows achieving excellent flame retardancy with reduced usage amounts, thereby preserving the mechanical integrity of the thermoplastic polyester resin
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-based flame retardant achieves flame retardancy equivalent to or better than conventional phosphorus-based flame retardants with reduced usage, while significantly enhancing mechanical properties such as tensile strength and impact strength of the thermoplastic resin.
Implementation Method 1
the phosphorus (P)-based flame retardant... may be used as a flame retardant or a flame retardant additive of a thermoplastic resin composition
Implementation Method 2
R4 includes at least one substituent capable of forming coordination bonding with the following M, wherein M is a metal selected from Group 1, Group 2, Group 3 and transition metals
Data Source
AI summary
A phosphorus (P)-based flame retardant, a thermoplastic resin composition and a molded article including the phosphorus-based flame retardant are provided. The phosphorus-based flame retardant, even if an amount of use is reduced compared to a conventional flame retardant, is capable of providing significantly improved mechanical properties such as tensile strength and impact strength, while exhibiting excellent flame retardancy.