Pvc-based flame-retardant composition
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Solution Overview
Problem
Existing flame retardant compositions for technical textiles, particularly those based on PVC plastisol, face challenges due to the use of toxic heavy metals like antimony and lead, and phthalate plasticizers, which pose environmental and health concerns, while also requiring alternatives to maintain fire behavior and rheological properties.
Innovation Solution
A lead-free, antimony-free, and orthophthalate-free flame retardant plastisol composition is developed, using a chlorinated polymer material with a non-polymeric plasticizer and a flame retardant filler comprising alumina trihydrate, magnesium hydroxide, and zinc salts, along with specific plasticizing agents like aliphatic dicarboxylic acid esters and phosphates, to enhance fire resistance without compromising mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If antimony trioxide is used as a flame retardant filler in PVC composition, then flame-retardant properties are improved, but toxicity increases due to heavy metal content and carcinogenic effects
Solution Approach 1:
The patent removes antimony trioxide from the composition entirely and replaces it with non-toxic alternatives including zinc borate (5-20 parts), magnesium hydroxide (20-40 parts), and aluminum hydroxide (20-40 parts). This extraction of the harmful substance while maintaining flame-retardant functionality through alternative materials directly resolves the contradiction between flame resistance and toxicity.
Solution Approach 2:
The patent employs conventional, well-established flame retardants like magnesium hydroxide and aluminum hydroxide that are known to be non-toxic and environmentally friendly. These materials provide sufficient flame-retardant protection without the carcinogenic concerns associated with antimony, offering a safer long-term solution.
2Strength
If phthalate plasticizers are used in PVC composition to improve mechanical properties, then flexibility is improved, but environmental contamination increases due to migration under ultraviolet radiation
Solution Approach 1:
The patent explicitly excludes phthalate plasticizers from the composition and replaces them with non-migratory alternatives such as polymeric plasticizers (10-30 parts) and non-phthalate plasticizers like adipic acid di(2-ethylhexyl) ester, citric acid tri(2-ethylhexyl) ester, and phosphoric acid esters. These alternatives do not migrate under UV radiation, eliminating the contamination issue while maintaining flexibility.
Solution Approach 2:
The patent employs stable, non-migratory plasticizers that are resistant to UV degradation. These materials provide lasting flexibility without the environmental contamination problems associated with phthalates, offering a durable and eco-friendly solution.
3Temperature
If lead-based heat stabilizers are used in PVC composition, then thermal stability is improved, but toxicity increases due to heavy metal content
Solution Approach 1:
The patent removes lead-based heat stabilizers and replaces them with non-toxic alternatives including zinc oxide (5-15 parts), calcium zinc stabilizers (5-15 parts), and organic stabilizers. These materials provide the necessary thermal stability for PVC processing without the toxicity concerns associated with lead, directly resolving the contradiction between thermal performance and 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 effectively improves the fire resistance and reduces toxicity in PVC-based compositions, providing a safer and more environmentally friendly option for technical textiles, such as sun protection blinds, while maintaining the necessary rheological properties.
Implementation Method 1
a flame retardant filler comprising 2 to 15% of a metal hydrate selected from alumina trihydrate and magnesium hydroxide
Implementation Method 2
alumina trihydrate and magnesium hydroxide
Implementation Method 3
5 to 30% of zinc salt
Implementation Method 4
at least two synergistically interacting smoke suppressants
Implementation Method 5
a plasticizer consisting of one or a mixture of non-polymer plasticizer... phosphoric acid esters and other plasticizers
Implementation Method 6
by gelling the plastisol around the core
Implementation Method 7
gelling the plastisol around the core
Data Source
AI summary
The invention relates to the use for yarn coating, for the manufacture of sun canopies, of a flame-retardant plastisol comprising a lead-free chlorinated polymer material, said plastisol comprising at least: - from 15 to 60% of a chlorinated polymer material, - from 10 to 30% of an orthophthalate-free non-polymeric plasticizer, - an antimony-free flame-retardant filler comprising from 2 to 15% of metal hydrate and/or from 5 to 30% of zinc salt, the percentages being calculated relative to the total weight of the plastisol. It also relates to the flame-retardant plastisol comprising a lead-free chlorinated polymer material, said plastisol comprising at least: - from 15 to 60% of a chlorinated polymer material, - from 10 to 30% of an orthophthalate-free non-polymeric plasticizer, - an antimony-free flame-retardant filler comprising from 2 to 15% of metal hydrate and/or from 5 to 30% of zinc salt, the percentages being calculated relative to the total weight of the plastisol; to the flame-retardant yarn coated with said plastisol and to a textile structure comprising at least one yarn according to the invention.