Polymerizable Flame Retardant Integration in Resin Matrix

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Solution Overview

Problem

Conventional phosphorus-containing flame retardants are non-reactive additives that may migrate or volatilize over time, reducing their performance and not fully integrating into the cured polymeric matrix, while halogen and metal-based flame retardants are harmful to the environment and human health.

Innovation Solution

A polymerizable flame retardant comprising (meth)acrylate-containing moieties and a phosphorus-containing moiety with more than one phosphorus atom, which can be combined with ethylenically unsaturated compounds and chemically bound to the resin matrix, providing improved flame resistance and reduced extractables without impairing curing or final product properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional phosphorus-containing flame retardants are used as non-reactive additives, then flame retardant performance is initially achieved, but the flame retardant migrates and volatilizes over time reducing performance

Engineering Contradiction:

Improveflame retardant performanceVSAvoidduration of flame retardant effectiveness

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent combines the flame retardant phosphorus compound with polymerizable (meth)acrylate groups, merging the flame retardant function with the curing chemistry. This integration allows the flame retardant to become part of the crosslinked polymer network through chemical bonding, preventing migration and volatilization while maintaining long-term effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flame retardant is pre-functionalized with (meth)acrylate groups before incorporation into the composition. This preliminary chemical modification enables the flame retardant to actively participate in the curing process and form permanent chemical bonds with the matrix, ensuring long-term stability rather than relying on physical containment.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If halogen or metal-based flame retardants are used to achieve flame resistance, then flame retardant performance is improved, but environmental harm increases

Engineering Contradiction:

Improveflame resistanceVSAvoidenvironmental harm

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameter by replacing halogen or metal-based flame retardants with phosphorus-containing compounds. This substitution maintains flame retardant effectiveness while eliminating the harmful environmental effects associated with halogen and metal-based alternatives.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the traditionally harmful halogen and metal-based flame retardants into environmentally benign phosphorus-containing compounds. The phosphorus compound achieves the same flame suppression function without the toxic byproducts and environmental persistence problems of halogenated substances.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If non-reactive flame retardant additives are used, then formulation simplicity is maintained, but integration into the cured matrix is incomplete

Engineering Contradiction:

Improveformulation simplicityVSAvoidintegration into cured matrix

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The flame retardant compound serves multiple functions simultaneously: it provides flame retardancy through phosphorus, participates in curing through (meth)acrylate groups, and becomes part of the crosslinked network. This multi-functionality eliminates the need for separate reactive diluents or coupling agents, maintaining formulation simplicity while achieving complete integration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 results in a cured product with enhanced flame resistance and heat resistance, and reduced extractables, while being environmentally friendly and fully integrated into the polymeric matrix, thus overcoming the limitations of conventional flame retardants.

Implementation Method 1

The (meth)acrylated flame retardant of the invention may advatageoulsy be combined with ethylenically unsaturated compounds, such as (meth)acrylate monomers and/or oligomers, without any compatibility issues and fully integrated in the cured polymeric matrix after exposure to radiation, such as UV, near-UV and/or visible radiation.

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS20240279381A1Polymerizable flame retardant

Publication Date: 2024.08.22 ARKEMA FRANCE SA

AI summary

The present invention relates to non-halogenated and non-metal polymerizable flame retardants, their preparation, compositions containing the same and uses thereof. These flame retardants may be polymerized with other ethylenically unsaturated compounds and chemically bound to the resin matrix thus limiting their migration out of the finished product. The flame retardants of the invention are also more environmentally friendly than conventional halogen-based or metal-based flame retardants.