PPS Resin Composition With Silicone Dispersion for Flame-Retardant Toughness
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Solution Overview
Problem
Polyphenylene sulfide (PPS) resin compositions that are both highly flame retardant and flexible and tough have not been achieved, as previous compositions either sacrifice flame retardance or toughness when attempting to enhance flexibility.
Innovation Solution
A PPS resin composition comprising a polyphenylene sulfide resin and a silicone-based polymer, with the silicone-based polymer dispersed in a phase-separated structure, maintaining a flexural modulus below 3.0 GPa and achieving a V-0 rating in the UL 94 standard for flame retardance, along with a tensile elongation at break of not less than 10%, using specific molecular weight ranges and processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an olefin elastomer is added to improve flexibility and toughness, then the resin composition becomes more flexible and tough, but the flame retardance is significantly reduced
Solution Approach 1:
The patent extracts the harmful effect of conventional elastomers by removing olefin elastomers and replacing them with thermoplastic elastomers that do not compromise flame retardance. This selective removal of problematic components while retaining desired functionality resolves the contradiction between toughness and flame retardance.
Solution Approach 2:
The patent creates a composite resin composition combining PPS resin with specific thermoplastic elastomers (polyester elastomer, polyamide elastomer, or polyurethane elastomer) in controlled amounts (5-30 parts by weight per 100 parts PPS). This composite approach achieves both improved toughness and maintained flame retardance (V-0 rating), unlike simple PPS or PPS with olefin elastomer.
2Ease of operation
If a thermoplastic elastomer and plasticizer are added to achieve flexibility, then the resin composition becomes flexible, but the flame retardance is reduced and V-0 rating cannot be achieved
Solution Approach 1:
The patent removes plasticizers from the formulation, as these low molecular weight compounds compromise flame retardance. Instead, flexibility is achieved through carefully selected thermoplastic elastomers that provide the required柔韧性 without sacrificing flame safety, maintaining V-0 rating even in thin-walled products (1.6mm or less).
Solution Approach 2:
The patent changes the type of elastomer used from conventional thermoplastic elastomers that compromise flame retardance to specific elastomers (polyester, polyamide, or polyurethane) with controlled molecular characteristics. By controlling the elastomer content at 5-30 parts per 100 parts PPS and specifying molecular weight ranges, the composition achieves flexibility while maintaining V-0 flame retardance.
3Weight of moving object
If the resin composition is made thinner for weight reduction, then weight is reduced, but maintaining flame retardance becomes more difficult
Solution Approach 1:
The patent develops a composite PPS resin composition with thermoplastic elastomers that maintains V-0 flame retardance even in thin-walled products (1.6mm or less). The specific formulation (PPS with 5-30 parts thermoplastic elastomer per 100 parts PPS, with elastomer molecular weight 10,000-1,000,000) ensures that flame retardance is not compromised by reduced thickness, enabling weight reduction while maintaining safety.
Data Source
AI summary
A polyphenylene sulfide resin composition includes (a) a polyphenylene sulfide resin and (b) a silicone-based polymer; the content of the component (b) is not less than 3 parts by weight and not more than 40 parts by weight with respect to 100 parts by weight of the component (a); in terms of morphology (phase structure), the polyphenylene sulfide resin composition has a phase-separated structure wherein the component (a) forms a continuous phase and the component (b) forms a dispersed phase in which the component (b) is dispersed with a number average dispersion diameter of not more than 3.0 μm; a test specimen obtained by injection molding of the polyphenylene sulfide resin composition at a cylinder temperature of 310° C. and a mold temperature of 145° C. has a flexural modulus of not more than 3.0 GPa as determined by a flexural test according to ISO 178.