Halogen-Free Flame Retardant TPU-OBC Composites
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Solution Overview
Problem
Thermoplastic polyurethane (TPU)-based halogen-free flame retardant compositions face challenges such as high cost, material density, and shrinkage issues when injection molded, with compatibility issues and decreased flame retardant performance when combined with conventional polyolefins, particularly due to polarity differences.
Innovation Solution
A halogen-free flame retardant composition comprising 25-50 wt% TPU, 5-50 wt% olefin block copolymer (OBC), and 30-70 wt% flame retardant, where TPU is the continuous phase, and OBC and flame retardant are dispersed, eliminating the need for a compatibilizer, and using specific flame retardants like resorcinol bis(diphenyl phosphate) and aluminum trihydrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If TPU is used to provide mechanical properties and flexibility, then mechanical performance is improved, but cost and material density increase
Solution Approach 1:
The patent uses a composite material system combining TPU with specific flame retardants (ATH, RDP, BDP, BPADP) to create a multi-functional material that simultaneously provides mechanical strength, flame retardancy, and reduced density compared to pure TPU formulations
2Strength
If TPU is used as the base material, then mechanical properties and flexibility are maintained, but shrinkage occurs during injection molding
Solution Approach 1:
The patent modifies the material composition parameters by incorporating flame retardants with different thermal and dimensional properties than pure TPU, which changes the shrinkage behavior during injection molding and improves dimensional stability of the final product
3Weight of stationary object
If conventional polyolefin is added to TPU to reduce cost, then material cost decreases, but compatibility and flame retardant performance deteriorate
Solution Approach 1:
The patent replaces expensive TPU-based formulations with a cost-effective composite system using conventional polyolefin as the base material combined with specific flame retardants, achieving comparable performance at lower cost without requiring TPU
Solution Approach 2:
The patent creates a composite material system using conventional polyolefin combined with specific flame retardants (ATH, RDP, BDP, BPADP) that overcomes the compatibility and performance issues of simple polyolefin blends by optimizing the composite composition
4Weight of stationary object
If conventional polyolefin is added to TPU to reduce cost, then material cost decreases, but flame retardant performance decreases
Solution Approach 1:
The patent optimizes the flame retardant composition parameters by selecting specific types (ATH, RDP, BDP, BPADP) and their ratios to achieve effective flame retardancy in the cost-reduced polyolefin-based formulation
Solution Approach 2:
The patent uses a composite material approach combining polyolefin with multiple flame retardant components that work synergistically to maintain or improve flame retardant performance despite the lower base material cost
Data Source
Figure 1A~2B
Figure 3~6
AI summary
The present disclosure provides a flexible, halogen-free, flame retardant composition. The composition includes from about 25 wt % to about 95 wt % of a thermoplastic polyurethane (TPU); from about 5 wt % to about 50 wt % of an olefin block copolymer (OBC); and from about 30 wt % to about 70 wt % of a flame retardant. The flame retardant is selected from resorcinol bis(diphenyl 5 phosphate) (RDP), bis diphenyl phosphate (BDP), bisphenol-A bis(diphenyl phosphate) (BPADP), aluminum trihydrate (ATH), a nitrogen/phosphorus-based halogen-free flame retardant, epoxidized novolac resin, and combinations thereof. The composition requires no compatibilizer for the TPU and OBC. The composition finds application in wire and cable structures.