Flame-Retardant Polyamide Composition for Thin-Wall Charging Components
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Solution Overview
Problem
Existing polyamide-based compositions for electrical components, particularly in charging components for electromobility, face challenges in achieving a UL94 V-0 flammability classification at wall thicknesses ≤0.75 mm while maintaining isotropic thermal conductivity of at least 1 W/mK and good mechanical properties such as flexural strength and impact resistance, without using boron nitride.
Innovation Solution
A composition comprising semicrystalline polyamides, aluminium oxide, magnesium hydroxide, and a halogen-free organic epoxidized compound with at least two epoxy groups per molecule, processed into moulding materials through mixing, extrusion, and injection moulding, achieving a UL94 V-0 flammability classification and isotropic thermal conductivity of at least 1 W/mK with improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If boron nitride is used to achieve high thermal conductivity and UL94 V-0 classification, then flammability and thermal conductivity requirements are met, but mechanical properties such as flexural strength and outer fibre strain become insufficient
Solution Approach 1:
The patent uses a composite filler system combining aluminium oxide and magnesium hydroxide in specific ratios (1:1 to 3:1 by weight) within polyamide matrix. This composite approach achieves UL94 V-0 flammability classification and thermal conductivity ≥1 W/mK while maintaining adequate mechanical properties, avoiding the mechanical weakness caused by boron nitride alone
Solution Approach 2:
The patent modifies the chemical composition parameters by using halogen-free organic epoxidized compounds (0.1-10 phr) as coupling agents and flame retardants, replacing traditional boron nitride-based formulations. This parameter change enables achieving flammability and thermal conductivity targets while preserving mechanical integrity through optimized chemical interactions in the composite
2Volume of moving object
If wall thickness is reduced to ≤0.75 mm to save space, then installation space requirement is met, but achieving UL94 V-0 classification becomes more difficult
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating halogen-free organic epoxidized compounds (0.1-10 phr) that enhance flame retardancy and thermal conductivity. This enables thin-walled components (≤0.75 mm) to achieve UL94 V-0 classification by optimizing the chemical properties of the material rather than relying on increased thickness
Solution Approach 2:
The patent employs a composite formulation with aluminium oxide, magnesium hydroxide, and polyamide in specific ratios, creating a material system that achieves high flame retardancy and thermal conductivity at reduced thicknesses, making thin-walled designs viable for space-constrained applications
3Reliability
If aluminium oxide and magnesium hydroxide are used as fillers, then flame retardancy is improved, but thermal conductivity may become insufficient
Solution Approach 1:
The patent optimizes the weight ratio parameters of aluminium oxide to magnesium hydroxide (1:1 to 3:1) and controls the total filler content (30-70 wt%) to balance flame retardancy and thermal conductivity. This parameter optimization ensures both UL94 V-0 classification and thermal conductivity ≥1 W/mK are achieved simultaneously
Solution Approach 2:
The patent creates a synergistic composite system where aluminium oxide provides thermal conductivity and magnesium hydroxide provides flame retardancy, with their combination in specific ratios achieving both thermal and flammability requirements. The polyamide matrix and coupling agents enhance the interfacial thermal transfer, ensuring adequate thermal conductivity while maintaining flame safety
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 polyamide-based composition that meets the desired flammability and thermal conductivity criteria while ensuring mechanical stability, flexibility, and impact resistance, suitable for charging components in electromobility.
Implementation Method 1
at least one organic epoxidized compound, in particular a polyglycidyl ether or a poly(beta-methylglycidyl) ether
Implementation Method 2
an isotropic thermal conductivity of at least 1 W/mK
Implementation Method 3
electrically insulating, thermally conductive plastics for more effective dissipation of the heat
Implementation Method 4
a UL94 V-0 classification is to be achieved even at very thin wall thicknesses
Data Source
AI summary
The present invention relates to flame retardant polyamide-based compositions or moulding materials and to articles of manufacture of the electricals or electronics industries producible therefrom, in particular charging components, containing at least one polyamide, aluminium oxide, magnesium hydroxide and at least one organic epoxide.