Polycarbonate Resin Composition for Flame Retardancy and Flow
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Solution Overview
Problem
Resin compositions containing recycled polycarbonate resins face issues with deteriorated physical properties, such as reduced fluidity and flame retardancy due to decreased molecular weight, leading to moldability degradation and potential dripping during combustion.
Innovation Solution
A resin composition comprising a polycarbonate resin, an organic sulfonic acid metal salt, and a phosphate ester, with a z-average molecular weight to weight average molecular weight ratio of 1.7 or more, promotes the formation of a carbonized layer and improves flame retardancy and fluidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If recycled polycarbonate resin is used to reduce resource waste and energy consumption, then environmental protection is improved, but molecular weight decreases causing deterioration of fluidity and flame retardancy
Solution Approach 1:
The patent changes the molecular weight distribution parameters of the polycarbonate resin by specifying that the ratio of z-average molecular weight to weight average molecular weight shall be 1.7 or more. This parameter control maintains adequate fluidity and flame retardancy even when using recycled materials, resolving the contradiction between environmental protection and performance reliability.
Solution Approach 2:
The patent creates a composite resin composition containing polycarbonate resin with specific molecular weight distribution, flame retardants, and other additives. This composite structure compensates for the performance degradation of recycled polycarbonate by incorporating functional additives that restore flame retardancy and fluidity properties.
2Ease of manufacture
If molecular weight is reduced in recycled polycarbonate resin, then processing becomes easier, but moldability deteriorates due to reduced melt tension
Solution Approach 1:
The patent optimizes the molecular weight distribution parameters by controlling the z-average molecular weight to weight average molecular weight ratio to be 1.7 or more. This specific parameter control maintains adequate melt tension for good moldability while allowing the use of lower molecular weight recycled materials that are easier to process.
3Quantity of substance
If molecular weight decreases in polycarbonate resin, then viscosity reduces improving fluidity, but flame retardancy deteriorates and dripping occurs during combustion
Solution Approach 1:
The patent formulates a composite resin composition that combines polycarbonate resin with flame retardant additives and other functional materials. This composite approach maintains good fluidity from the lower viscosity resin while compensating for flame retardancy loss through the additive system, preventing dripping during combustion.
Solution Approach 2:
The patent controls the molecular weight distribution parameters (z-average molecular weight to weight average molecular weight ratio of 1.7 or more) to optimize the balance between viscosity and flame retardancy, ensuring adequate performance in both aspects despite using lower molecular weight recycled materials.
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 composition achieves satisfactory flame retardancy and fluidity, meeting UL94 V-1 standards, while maintaining impact strength and moldability.
Implementation Method 1
promotes the formation of a carbonized layer and improves flame retardancy and fluidity
Data Source
AI summary
An object of the present invention is to provide a resin composition having satisfactory flame retardancy and fluidity. The resin composition includes a polycarbonate resin, a organic sulfonic acid metal salt, and a phosphate ester, and a ratio of a z-average molecular weight of the polycarbonate resin to a weight average molecular weight of the polycarbonate resin is 1.7 or more.