Flame retardant resin composition and method for producing the same
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Solution Overview
Problem
Conventional flame retardant processing methods for fiber-reinforced resins are insufficient in achieving sufficient flame resistance without using halogen flame retardants, and they often suffer from the 'candle effect' where fibers promote burning.
Innovation Solution
A non-halogen flame retardant resin composition is developed using thermoplastic resin, flame retardant reinforced fibers with phosphorus and polyamine compounds bonded to cellulosic fibers, and a phosphorus-based flame retardant, which are produced through electron beam irradiation and subsequent treatment processes to enhance flame and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional flame retardant processing methods are used with vegetable fibers, then the fiber reinforced resin achieves light weight and high stiffness, but the fibers serve as conductors and promote burning through the candle effect
Solution Approach 1:
The patent applies local quality by treating only the fiber surfaces with phosphorus and polyamine compounds through electron beam irradiation, rather than treating the entire resin matrix. This localized treatment on the fiber surfaces prevents the candle effect while maintaining the structural integrity and stiffness of the fiber reinforced resin.
Solution Approach 2:
The patent creates a composite structure by combining cellulosic fibers with phosphorus compounds and polyamine compounds on the fiber surfaces. This composite approach forms a flame retardant coating on the fibers that prevents burning while preserving the mechanical properties of the original fiber reinforced resin.
2Object-affected harmful factors
If halogen flame retardants are used to achieve sufficient flame resistance, then the flame resistance is improved, but the use of halogen compounds is restricted and costs increase
Solution Approach 1:
The patent changes the chemical parameters by using phosphorus-based compounds instead of halogen-based compounds. The electron beam irradiation activates the phosphorus compounds to bond with the fiber surfaces, creating effective flame retardancy without requiring halogen elements, thus avoiding the associated cost and regulatory issues.
Solution Approach 2:
The patent replaces the chemical mechanism of halogen flame retardants with a phosphorus-polyamine chemical system activated by electron beam irradiation. This substitution eliminates the need for halogen compounds while achieving comparable or superior flame resistance, reducing manufacturing costs and regulatory compliance burden.
3Object-affected harmful factors
If only phosphorus is covalently bonded to cellulosic fibers to make them flame retardant, then the flame resistance is improved, but the heat resistance is reduced
Solution Approach 1:
The patent merges phosphorus compounds and polyamine compounds on the fiber surfaces through electron beam irradiation. This combination creates a synergistic effect where phosphorus provides flame retardancy while polyamine maintains heat resistance, achieving both goals simultaneously rather than sacrificing one for the other.
Solution Approach 2:
The patent creates a composite coating on the cellulosic fibers consisting of phosphorus compounds bonded to the fiber surface and polyamine compounds bonded to the phosphorus compounds. This composite structure on the fiber surface provides both flame resistance and heat resistance, overcoming the limitation of using only phosphorus treatment.
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 a non-halogen flame retardant resin composition with improved flame resistance, reduced heat degradation, and cost-effectiveness by making cellulosic fibers flame retardant, allowing for a broader choice of thermoplastic resins and maintaining high heat resistance.
Implementation Method 1
by bringing the vinyl phosphate compound into contact with the cellulosic fibers after the cellulosic fibers have been irradiated with an electron beam
Implementation Method 2
grafting a vinyl phosphate compound to cellulosic fibers by bringing the vinyl phosphate compound into contact with the cellulosic fibers after the cellulosic fibers have been irradiated with an electron beam
Data Source
AI summary
A flame retardant resin composition includes a thermoplastic resin, flame retardant reinforced fibers, and a flame retardant. The flame retardant reinforced fibers include cellulosic fibers, a phosphorus compound that is grafted to the surface of the cellulosic fibers, and a polyamine compound that is bound to the phosphorus compound. The flame retardant is a phosphorus-based flame retardant. A method for producing the flame retardant resin composition includes the following: grafting a vinyl phosphate compound to cellulosic fibers by bringing the vinyl phosphate compound into contact with the cellulosic fibers after the cellulosic fibers have been irradiated with an electron beam, optionally followed by electron beam irradiation; binding a polyamine compound to the vinyl phosphate compound, which is grafted to the cellulosic fibers, to form flame retardant reinforced fibers; grinding the flame retardant reinforced fibers; and melt-kneading and pelletizing a thermoplastic resin, the flame retardant reinforced fibers, and a component containing a phosphorus-based flame retardant. This can provide a non-halogen flame retardant resin composition with sufficient flame resistance.