Styrene Resin Flame Retardant Composition

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Styrene resins, commonly used in electric and electronic products, are inherently combustible and lack flame retardancy, with halogen-based flame retardants offering high efficiency but deteriorating at high temperatures and pressures, while non-halogen alternatives require excessive amounts to meet flame retardancy standards.

Innovation Solution

A non-halogen flame retardant composition for styrene resins incorporating an epoxy resin with a specific repeat unit, combined with a non-halogen flame retardant compound, which passes the IEC TS 62441 external candle flame ignition standard without using excessive amounts of the flame retardant, enhancing thermal stability and mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogen flame retardants are used to achieve high flame retardancy efficiency, then flame retardancy is improved, but thermal stability deteriorates and toxic corrosive gases are generated at high temperatures

Engineering Contradiction:

Improveflame retardancyVSAvoidtoxic corrosive gases

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by using a specific epoxy resin (Formula 1) with particular structural parameters (n1, n2, n3, n4 values) combined with non-halogen flame retardant compounds, replacing halogen-based systems to eliminate toxic gas generation while maintaining flame retardancy

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite flame retardant system combining epoxy resin (Formula 1) with non-halogen flame retardant compounds such as phosphorous, nitrogen, or hydroxide-based additives, achieving synergistic effects that provide both flame retardancy and thermal stability without toxic emissions

Inventive Principle:

Principle #40Composite materials

2Object-generated harmful factors

If non-halogen flame retardant compounds are used to avoid toxic gases, then harmful factors are reduced, but excessive amounts are required to achieve sufficient flame retardancy

Engineering Contradiction:

Improvetoxic corrosive gasesVSAvoidflame retardant compound amount

Core Design Contradiction:

Object-generated harmful factorsVSQuantity of substance

Solution Approach 1:

The patent optimizes the structural parameters of the epoxy resin (Formula 1) including the values of n1, n2, n3, and n4 to enhance flame retardancy efficiency, allowing effective flame protection with reduced amounts of non-halogen flame retardant compounds

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces specific functional groups and structural features at key positions within the epoxy resin molecule (represented by R1-R6, X, Y, and Z parameters) to locally enhance flame retardant properties, improving overall efficiency without requiring excessive additive amounts

Inventive Principle:

Principle #3Local quality

3Strength

If phosphorous-based flame retardant systems are used to avoid char production, then mechanical properties are maintained, but flame retardancy is insufficient

Engineering Contradiction:

Improvemechanical propertiesVSAvoidflame retardancy

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent combines epoxy resin (Formula 1) with complementary flame retardant mechanisms that work synergistically to produce protective char layers while maintaining mechanical integrity, overcoming the limitation of phosphorous-only systems

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical structure parameters of the epoxy resin to enable controlled char formation that enhances flame retardancy while preserving mechanical strength through optimized molecular architecture

Inventive Principle:

Principle #35Parameter changes

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 composition effectively achieves flame retardancy that meets the IEC TS 62441 standard, producing char and maintaining mechanical strength and thermal stability without excessive non-halogen flame retardant usage, while also improving flowability and gloss.

Implementation Method 1

thermoplastic resin compositions which do not produce char due to the principle of phosphorous-based flame retardant systems cannot sufficiently exert flame retardancy

Methodology Applied

Scientific EffectChar production: Pyrolysis

Data Source

PatentEP2743308B1Flame retardant and flame retardant composition for styrene resins

Publication Date: 2016.10.26 LG CHEM LTD

AI summary

Disclosed are a flame retardant for a styrene resin and a flame retardant composition comprising the same. More specifically, disclosed are a flame retardant for a styrene resin which comprises a non-halogen flame retardant compound and an epoxy resin having a repeat unit represented by Formula 1 and thus passes the IEC TS 62441 flame retardancy standard of external candle flame ignition without using the non-halogen flame retardant compound in an excessive amount, and a flame retardant composition comprising the same.