Polyolefin Foam Particles Flame Retardancy Carbon Black
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Solution Overview
Problem
Conventional in-mold expanding molded products using carbon black for black coloration often compromise on flame retardancy and moldability, requiring expensive halogen-free flame retardants and experiencing issues with internal pressure variations leading to surface wrinkles and gaps.
Innovation Solution
Development of polyolefin resin expanded particles incorporating a specific phosphorous-based flame retardant and carbon black, which maintains flame retardancy while reducing production losses and ensuring a wide range of molding conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If carbon black is used for black coloration in in-mold expanding molded products, then tinting strength and heat resistance are improved, but flame retardancy deteriorates
Solution Approach 1:
The patent uses a composite flame retardant system combining phosphorous-based flame retardant (1-5 parts by weight) and nitrogen-containing flame retardant (5-20 parts by weight) to achieve synergistic flame retardancy in the presence of carbon black (2-10 parts by weight). This composite approach allows the molded product to maintain both black coloration and flame retardancy by creating a multi-component fire suppression mechanism that works effectively alongside carbon black.
2Object-affected harmful factors
If non-halogen flame retardants are used in large amounts to achieve flame retardancy, then harmful gas emission is reduced, but mechanical properties and moldability deteriorate
Solution Approach 1:
The patent optimizes the dosage parameters of flame retardants to achieve effective flame retardancy with minimal impact on moldability. Specifically, phosphorous-based flame retardant is used at 1-5 parts by weight and nitrogen-containing flame retardant at 5-20 parts by weight, which are carefully controlled ranges that provide sufficient fire protection while maintaining the resin's flow and molding characteristics.
Solution Approach 2:
By combining phosphorous-based and nitrogen-containing flame retardants in specific proportions, the patent creates a synergistic system that achieves flame retardancy at lower total concentrations than single-component systems would require, thereby preserving mechanical properties and moldability.
3Loss of energy
If internal pressure of polyolefin resin expanded particles is decreased, then production cost is reduced, but surface quality deteriorates due to wrinkles and gaps
Solution Approach 1:
The patent identifies and controls critical process parameters including internal pressure of expanded particles, molding temperature, and flame retardant composition to achieve stable surface quality. By optimizing these parameters within specific ranges, the process can produce high-quality molded products even when internal pressure of expanded particles is reduced, preventing wrinkles and gaps through balanced process conditions.
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 achieves satisfactory flame retardancy in FMVSS302 tests, maintains excellent surface appearance, and reduces production losses, making the process more cost-effective and productive.
Implementation Method 1
a flame-retardant polyolefin resin expanded particle containing a phosphorous-based flame retardant whose 5% by weight decomposition temperature falls within a range of 240°C to 320°C
Implementation Method 2
fusing the polyolefin resin expanded particles by heating
Implementation Method 3
the polyolefin resin expanded particles are heated with use of heated steam
Data Source
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AI summary
In order to obtain a flame-retardant polyolefin resin expanding molded product which has excellent in-mold moldability and excellent surface appearance and satisfies the FMVSS flammability even if carbon black is added, polyolefin resin particles containing, with respect to 100 parts by weight of polyolefin resin, (i) 0.03 part by weight to 5 parts by weight of phosphorous flame retardant having a phosphorous content of 7% by weight or more, a melting point of 120°C or more, and a 5% by weight decomposition temperature within a range of 240°C to 320°C and (ii) 0.5 part by weight to 20 parts by weight of carbon black are expanded.