Flame-Retardant PPE-PS Composite for Strength and Processability
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Solution Overview
Problem
Existing high-temperature, corrosion-resistant, and flame-retardant composite materials for photovoltaic connectors face challenges in maintaining mechanical strength and processability while ensuring adequate flame retardancy and aging resistance, often requiring high amounts of additives that compromise these properties.
Innovation Solution
A high-strength and high-toughness flame-retardant thermoplastic PPE-PS composite material is developed, comprising 100 parts of PPE resin, 8-15 parts of HIPS resin, 8-13 parts of halogen-free flame retardant, 0.5-3 parts of lubricant/dispersant, 0.5-2 parts of anti-UV agent, 2-8 parts of toughener, 0.5-2 parts of compatibilizer, and 0-2 parts of other auxiliary agents, with specific SEBS and flame retardant compositions to enhance processability and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If HIPS resin is added to improve processability, then fluidity and processability are improved, but flame retardancy is significantly reduced
Solution Approach 1:
The patent introduces a compatibilizer (maleic anhydride-grafted PPE or PS) as an intermediary substance between PPE and HIPS/SEBS. This compatibilizer improves the interface compatibility and dispersion of HIPS and SEBS in the PPE matrix, allowing for lower amounts of HIPS to be used while maintaining processability, thereby reducing the negative impact on flame retardancy.
Solution Approach 2:
The patent changes the chemical parameter of the polymer blend by introducing grafted maleic anhydride groups on PPE or PS. This chemical modification enables better compatibility between polar PPE and non-polar HIPS/SEBS, improving interfacial adhesion and allowing for optimized formulation with reduced HIPS content to maintain both processability and flame retardancy.
2Reliability
If flame retardant is added to maintain flame retardancy, then flame retardancy is maintained, but tensile strength and impact strength are reduced
Solution Approach 1:
The compatibilizer acts as a mediator that improves the dispersion and interface compatibility of flame retardant particles in the polymer matrix. This better dispersion reduces agglomeration and stress concentration points, thereby minimizing the negative impact on tensile and impact strength while maintaining effective flame retardancy.
Solution Approach 2:
The patent creates a multi-component composite system comprising PPE, HIPS, SEBS, flame retardant, and compatibilizer. This composite structure allows for synergistic effects where the compatibilizer enhances the matrix-flame retardant interface, and the elastomeric modifiers (HIPS and SEBS) provide toughness that compensates for the strength reduction caused by flame retardant addition.
3Ease of manufacture
If HIPS content is increased to improve processability, then fluidity is improved, but aging resistance is reduced due to oxidation of HIPS
Solution Approach 1:
The patent extracts the primary aging vulnerability by limiting the HIPS content to a low range (3-15 parts per 100 parts PPE). By removing excess HIPS that would undergo oxidation, the patent reduces the generation of oxygen-containing groups that accelerate aging, while still maintaining adequate processability through the combined effect of HIPS and SEBS.
Solution Approach 2:
The patent replaces a significant portion of HIPS with SEBS, which has better aging resistance. While SEBS may have different cost characteristics, it serves as a more durable component in the long term, reducing the need for frequent replacement of aged components and improving the overall service life of the composite material.
4Strength
If PPE is used to maintain strength and flame retardancy, then mechanical strength and flame retardancy are maintained, but processability is difficult due to high melting point
Solution Approach 1:
The patent creates a composite material system that combines PPE with processability-enhancing components (HIPS and SEBS) and a compatibilizer. This composite structure allows the PPE matrix to maintain its inherent high strength and flame retardancy, while the dispersed HIPS and SEBS phases, along with improved interfacial compatibility, reduce the overall melt viscosity and improve processability.
Data Source
AI summary
The present invention relates to a high-strength, warping-resistant, flame-retardant PC composite material and application thereof. Raw materials for preparing the high-strength, warping-resistant, flame-retardant PC composite material provided by the present invention include the following components by weight: 100 parts of PC, 7-15 parts of a reinforcer, 1-8 parts of a toughener; 3-12 parts of a fire retardant, 0.1-3 parts of an antioxidant; 0.1-3.5 parts of a lubricant, and 0-3 parts of another processing aid, wherein the PC is a composite PC raw material obtained by mixing PC raw materials of different viscosities; the reinforcer includes a glass fiber and a glass microsphere, and a mass ratio of the glass fiber to the glass microsphere is 1:(0.5-1.5). With excellent tensile strength, bending strength, modulus, impact strength and other properties, the composite material provided by the present invention is a high-performance composite material with high strength and rigidity.