Flame-Retardant PK Molded Parts That Hold Shape Under Fire
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Solution Overview
Problem
Current thermoplastics used in electrical devices, such as electric vehicles and power tools, face limitations in temperature resistance and mechanical stability, particularly during thermal runaway events, where they can melt and lose functionality, and existing crosslinking methods using diamines pose hazards and are costly.
Innovation Solution
A crosslinked aliphatic polyketone (PK) polymer matrix combined with a special diamine source to form imine groups and at least one flame retardant, enhancing mechanical properties, heat resistance, and flame retardancy, while maintaining processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastics are used in electrical devices, then processability and manufacturing ease are improved, but temperature resistance and mechanical stability deteriorate during thermal runaway events
Solution Approach 1:
The patent applies parameter changes by modifying the polymer structure through crosslinking. The thermoplastic polymer chains are chemically crosslinked to form a three-dimensional network structure, fundamentally changing the material's thermal and mechanical parameters. This crosslinking transformation enables the material to maintain structural integrity at high temperatures while retaining processability during manufacturing.
Solution Approach 2:
The patent creates a composite material system combining thermoplastic polymer matrix with crosslinking agents and flame retardant additives. This composite structure integrates the processability advantages of thermoplastics with the thermal stability of crosslinked networks, achieving a material that exhibits both ease of manufacture and high temperature resistance.
2Temperature
If conventional crosslinking methods using diamines are used, then temperature resistance is improved, but safety hazards and manufacturing cost increase
Solution Approach 1:
The patent employs inexpensive, readily available crosslinking agents that can be easily handled and processed. These crosslinking agents are designed to be safe, non-toxic, and environmentally friendly, replacing hazardous conventional diamines. The approach prioritizes safety and cost-effectiveness while achieving the desired crosslinking effect for improved temperature resistance.
Solution Approach 2:
The patent introduces safe intermediary crosslinking agents that mediate the crosslinking process without the hazards of conventional diamines. These intermediaries provide the necessary chemical functionality for crosslinking while being inherently safer to handle, store, and process, thereby reducing safety hazards during manufacturing.
3Object-affected harmful factors
If flame retardants are added to thermoplastics, then flammability is reduced, but mechanical properties and processability deteriorate
Solution Approach 1:
The patent merges multiple functions into a unified material system. Flame retardants are integrated into the crosslinked polymer matrix in such a way that they work synergistically with the crosslinked structure to maintain mechanical properties. The combination of crosslinking and flame retardant addition creates a synergistic effect where the flame retardancy is achieved without significant compromise to mechanical strength and processability.
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 improved temperature resistance, reduced flammability, increased stiffness, and enhanced dimensional stability under direct flame exposure, preventing the spread of fire and maintaining structural integrity in electrical devices.
Implementation Method 1
a crosslinked aliphatic polyketone (PK) in combination with at least one flame retardant
Implementation Method 2
crosslinking an aliphatic polyketone with at least one diamine source as a crosslinking agent to form imine groups
Implementation Method 3
at least one flame retardant, enhancing mechanical properties, heat resistance, and flame retardancy
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a device for storage, generation, transmission, distribution and/or use of electrical energy, comprising a flame retardant molded article, comprising a polymer matrix containing a crosslinked aliphatic polyketone (PK) in combination with at least one flame retardant and to a method for improving the flame retardant properties of molded articles for electrical devices. The present invention further relates to electric vehicles, battery energy storage systems, power tools and devices for power generation and to parts therof, comprising a flame retardant molded article, comprising a polymer matrix containing a crosslinked aliphatic polyketone (PK) in combination with at least one flame retardant.