Polyolefin Foam Non-Halogen Flame Retardance Flexibility
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Solution Overview
Problem
Polyolefin-based resin foams face challenges in achieving both high flame retardance and compression flexibility while being non-halogen, non-phosphorus, and non-antimony, with existing solutions compromising on flexibility due to the addition of metal oxide or hydroxide flame retardants.
Innovation Solution
A polyolefin-based resin foam is developed by crosslinking and foaming a composition containing polyolefin-based resin, organic, and inorganic fillers, specifically using magnesium hydroxide, titanium oxide, melamine cyanurate, and carbon black, which achieves 25% compression hardness of 8 kPa or less and 25% compression set of 7% or less, without phosphorus or antimony compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal oxide or hydroxide flame retardants are added to polyolefin-based resin foam, then flame retardance is improved, but compression flexibility deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of flame retardants by selecting specific metal hydroxides (magnesium hydroxide, aluminum hydroxide) and organic flame retardants (melamine cyanurate, phosphorus-free compounds) with controlled particle sizes and distributions, achieving both flame retardance and compression flexibility without using halogenated compounds
Solution Approach 2:
The patent creates a composite flame retardant system combining multiple inorganic hydroxides with organic flame retardants in specific ratios, where magnesium hydroxide (10-30 parts) and aluminum hydroxide (70-90 parts) work synergistically with melamine cyanurate (5-20 parts) to provide both flame resistance and maintain the foam's compression properties
2Object-affected harmful factors
If non-halogen flame retardants are used, then environmental safety is improved, but flame retardance performance deteriorates
Solution Approach 1:
The patent introduces phosphorus-free flame retardants (melamine cyanurate, melamine polyphosphate) as intermediary substances that bridge the gap between environmental safety requirements and flame retardance performance, working in conjunction with metal hydroxides to achieve UL94 V-0 rating without halogen or phosphorus compounds
Solution Approach 2:
The patent optimizes the particle size distribution and surface treatment of inorganic flame retardants to enhance their flame retarding efficiency, achieving high flame safety performance with non-halogen compounds by controlling the dispersion and reactivity parameters of the flame retardant particles
3Reliability
If high amounts of inorganic filler are added, then flame retardance is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent applies local quality enhancement by using surface-treated inorganic fillers with improved interfacial adhesion to the polyolefin matrix, where the filler particles are locally optimized with coupling agents or surface coatings to maintain mechanical strength while providing flame retardance
Solution Approach 2:
The patent creates a multi-phase composite structure combining polyolefin resin with specifically proportioned inorganic fillers (magnesium hydroxide 10-30 parts, aluminum hydroxide 70-90 parts) and organic flame retardants, where the composite architecture distributes stress and prevents catastrophic failure while achieving 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 polyolefin-based resin foam that effectively balances flame retardance and compression flexibility, meeting the demands for non-halogen, non-phosphorus, and non-antimony requirements, suitable for various industrial applications.
Implementation Method 1
contains 100 to 150 parts by mass of magnesium hydroxide and 70 to 90 parts by mass of aluminum hydroxide
Implementation Method 2
Mg(OH)2 → MgO + H2O (endothermic decomposition)
Implementation Method 3
contains 5 to 20 parts by mass of melamine cyanurate
Implementation Method 4
contains 1 to 10 parts by mass of carbon black
Data Source
AI summary
The present invention provides a polyolefin-based resin foam that achieves both flame retardance and compression flexibility at a high level while satisfying a demand for achieving non-halogen (preferably, including non-phosphorus and non-antimony). The present invention is a non-halogen flame retardant resin foam made by crosslinking and foaming a polyolefin-based resin composition, a polyolefin-based resin foam having a 25% compression hardness in a thickness direction of 8 kPa or less as measured in accordance with JIS K6767, wherein the polyolefin-based resin composition contains a polyolefin-based resin, an organic filler and an inorganic filler, a total amount of compounding the organic filler and the inorganic filler being 100 to 200 parts by mass based on 100 parts by mass of the polyolefin-based resin.