Urethane Resin Composition for Red-Phosphorus-Free Flame Retardancy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing urethane resin compositions containing red phosphorus as a flame retardant face challenges in cost reduction and limited coloring options due to the red hue, and conventional fire-resistant coatings applied to urethane foam have issues with adhesion and application time.
Innovation Solution
A urethane resin composition comprising a polyisocyanate compound, polyol compound, catalyst, foaming agent, ammonium polyphosphate, and phosphoric ester, without red phosphorus, achieving flame retardancy through optimized ratios of these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If red phosphorus is used as a flame retardant in urethane resin composition, then flame retardancy is achieved, but cost increases and coloring freedom is restricted due to red hue
Solution Approach 1:
The patent changes the chemical composition parameters by replacing red phosphorus with a combination of ammonium polyphosphate and phosphoric ester in specific ratios (20-75 parts ammonium polyphosphate and 40-80 parts phosphoric ester per 100 parts polyol compound). This parameter change achieves the same flame retardancy function while eliminating the red coloration and reducing material costs.
Solution Approach 2:
The patent uses a composite flame retardant system combining ammonium polyphosphate and phosphoric ester together with specific polyol compounds and polyisocyanate compounds. This composite material approach provides synergistic flame retardancy effects that match or exceed red phosphorus performance without the associated cost and coloring drawbacks.
2Reliability
If red phosphorus is used as a flame retardant in urethane resin composition, then flame retardancy is achieved, but coloring freedom is restricted due to red hue
Solution Approach 1:
The patent changes the chemical composition parameters by replacing red phosphorus with ammonium polyphosphate and phosphoric ester. This parameter change eliminates the red coloration inherent to red phosphorus, thereby restoring full coloring freedom and design flexibility while maintaining the required flame retardancy performance.
Solution Approach 2:
The patent extracts and removes the problematic red phosphorus component from the urethane resin composition while retaining the essential flame retardancy function through alternative chemicals. This extraction eliminates the unwanted red hue that restricts coloring freedom and design options.
3Reliability
If conventional fire-resistant coatings are applied to urethane foam, then flame retardancy is improved, but application time increases and adhesion problems occur
Solution Approach 1:
The patent merges the flame retardant function directly into the urethane resin composition itself by incorporating ammonium polyphosphate and phosphoric ester during the foam formation process. This integration eliminates the need for separate post-application coatings, thereby reducing total application time and ensuring uniform flame protection throughout the material.
Solution Approach 2:
The patent applies flame retardancy in advance during the urethane foam manufacturing process rather than as a subsequent treatment. By incorporating flame retardant chemicals into the resin composition before foam formation, the flame protective function is built-in from the start, eliminating later application steps and associated time losses.
4Reliability
If conventional fire-resistant coatings are applied to urethane foam, then flame retardancy is improved, but adhesion is insufficient causing coating to fall off
Solution Approach 1:
The patent merges the flame retardant functionality directly into the urethane resin matrix through chemical incorporation of ammonium polyphosphate and phosphoric ester. This integration ensures that flame protection is inherently bonded to the foam structure at the molecular level, eliminating adhesion problems that plague surface-applied coatings.
Solution Approach 2:
The patent uses the urethane resin composition itself as an intermediary medium that uniformly distributes and bonds flame retardant chemicals throughout the foam structure. This intermediary approach ensures strong, uniform adhesion of flame protective function throughout the entire material volume rather than relying on weak surface bonding.
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 provides predetermined flame retardancy without the cost and color limitations of red phosphorus, meeting uninflammable or quasi-uninflammable standards in ISO-5660 heat release tests, with improved adhesion and application efficiency.
Implementation Method 1
ammonium polyphosphate, and phosphoric ester, the urethane resin composition being free from red phosphorus
Data Source
AI summary
For achieving a predetermined flame retardancy, a urethane resin composition comprises a polyisocyanate compound, a polyol compound, a catalyst, a foaming agent, ammonium polyphosphate, and phosphoric ester, and is free from red phosphorus.