A reference flame retardant formulation yeSK Polyester ES500 (UL94 V0 rating).
I. Nzira Yekugadzira Dhizaini
- Substrate Kugarisana
- SK Polyester ES500: Iyo thermoplastic polyester ine yakajairwa kugadzirisa tembiricha ye220–260°C. Chidziviriro chemoto chinofanirwa kutsungirira tembiricha iyi.
- Zvinodikanwa Zvinokosha: Balance flame retardancy (V0), mechanical properties (tensile/impact simba), uye kugadzirisa fluidity.
- Synergistic Flame Retardant System
- Ultrafine Aluminium Hydroxide (ATH): Primary flame retardant, endothermic dehydration. Kurodha kunofanirwa kuenzanisa kudzoreredza kwemurazvo uye ma mechanical properties.
- Aluminium Hypophosphite: Char-forming synergist, inoshanda neATH kugadzira phosphorus-aluminium synergistic effect, inovandudza char quality.
- Zinc Borate: Char enhancer, inodzvinyirira utsi, uye inoumba dense chipingamupinyi neATH.
- MCA (Melamine Cyanurate): Gas-phase flame retardant, dilutes oxygen uye inhibits kunyungudika kudonha.
II. Yakakurudzirwa Magadzirirwo (Weight Percentage)
| Chikamu | Ratio | Processing Notes |
|---|---|---|
| SK Polyester ES500 | 45–50% | Base resin; sarudza yakakwira-fluidity giredhi kutsiva filler viscosity. |
| Ultrafine ATH | 25–30% | Nzvimbo-yakagadziriswa ne silane coupling agent (KH-550), D50 <3 μm. |
| Aluminium Hypophosphite | 10–12% | Inodzivirira kupisa (> 300 ° C), yakasanganiswa neATH uye yakawedzerwa mumatanho. |
| Zinc Borate | 6–8% | Yakawedzerwa neMCA kudzivirira yakakwira-kuveura kukuvara kwechimiro. |
| MCA | 4–5% | Process tembiricha <250°C, yakaderera-speed dispersion. |
| Dispersant | 2–3% | Polyester-compatible dispersant (semuenzaniso, BYK-161) + polyethylene wax inoumbwa. |
| Coupling Agent (KH-550) | 1% | Pre-inobata ATH uye aluminium hypophosphite; kunyudzwa kwe ethanol kuchiteverwa nekuomeswa. |
| Anti-Dripping Agent | 0.5–1% | PTFE micropowder kudzvanya kunyungudika kupisa. |
| Processing Aid | 0.5% | Zinc stearate (kuzora uye anti-kunamatira). |
III. Key Process Controls
- Dispersion Optimization
- Pre-therapy: Soak ATH nealuminium hypophosphite mu1% KH-550 ethanol solution kwemaawa maviri, wozoomesa pa80°C.
- Mixing Sequence:
- Base resin + dispersant + coupling agent → Low-speed mixing (500 rpm, 5 min).
- Wedzera yakagadziridzwa ATH/aluminium hypophosphite → High-speed shear (2500 rpm, 20 min).
- Wedzera zinc borate/MCA/PTFE → Kusanganisa-kumhanya kwakaderera (800 rpm, 10 min).
- Zvishandiso: Twin-screw extruder (tembiricha nzvimbo: feed zone 200 ° C, melting zone 230 ° C, kufa 220 ° C).
- Kugadzirisa Temperature Control
- Iva nechokwadi chekunyunguduka kwepamusoro <250 ° C kudzivirira MCA kuora (MCA inoora pa250-300 ° C).
- Mvura-inotonhorera pellets mushure me extrusion kudzivirira murazvo unodzora kutama.
IV. Flame Retardant Synergistic Mechanism
- ATH + Aluminium Hypophosphite
- ATH inobata kupisa uye inoburitsa mhute yemvura, ichideredza magasi anobvira.
- Aluminium hypophosphite inokonzeresa dense char kuumbwa (AlPO₄), ichivharira kupisa kupisa.
- Zinc Borate + MCA
- Zinc borate inogadzira chinodzivirira chegirazi pamusoro pekutsemuka kwechar.
- MCA inoora kuburitsa NH₃, kunyungudutsa okisijeni uye kuvharidzira mahara radical reactions.
- PTFE Anti-Dripping
- PTFE micropowder inoumba fibrous network, inoderedza kunyunguduka-kudonha kwemoto njodzi.
V. Performance Tuning & Troubleshooting
| Common Nyaya | Solution |
|---|---|
| Kunonoka kwemurazvo pasi peV0 (V1/V2) | Wedzera aluminium hypophosphite kusvika 12% + MCA kusvika 5%, kana kuwedzera 2% yakavharidzirwa tsvuku phosphorus (synergistic nealuminium hypophosphite). |
| Yakaderedzwa mechanical properties | Deredza ATH kusvika 25%, wedzera 5% girazi fiber (kusimbisa) kana 3% maleic anhydride-grafted POE (inoomesa). |
| Kutadza kugadzirisa fluidity | Wedzera dispersant kusvika 3%, kana kuwedzera 0.5% yakaderera-MW polyethylene wax (kuzora). |
| Kubukira kwepamusoro | Natsiridza kubatanidza mumiriri dosage kana chinja kune titanate coupling agent (NDZ-201) kuti ive nani pakati pechiso chekubatana. |
VI. Validation Metrics
- UL94 V0 Muedzo:
- 1.6 mm uye 3.2 mm zvienzaniso, nguva yekupisa yakazara <50 sec mushure mekubatidza kaviri, hapana kupisa kunodonha.
- LOI: Target ≥30% (chaiyo ≥28%).
- Mechanical Properties:
- Tensile simba> 40 MPa, simba rekuita> 5 kJ/m² (ASTM standard).
- Thermal Kugadzikana (TGA):
- Char residue pa800°C > 20%, tembiricha yekuora kwekutanga> 300°C.
VII. Muenzaniso Reference Formulation
| Chikamu | Zvirimo (%) |
|---|---|
| SK Polyester ES500 | 48% |
| Ultrafine ATH (yakagadziridzwa) | 28% |
| Aluminium Hypophosphite | 11% |
| Zinc Borate | 7% |
| MCA | 4% |
| BYK-161 Dispersant | 2.5% |
| KH-550 Coupling Agent | 1% |
| PTFE Anti-Dripping Agent | 0.8% |
| Zinc Stearate | 0.5% |
Uku kuumbwa uye dhizaini dhizaini inobudirira kuwana UL94 V0 murazvo wekudzoka kweSK Polyester ES500 uku uchienzanisa processability uye michina zvivakwa. Miyedzo midiki-diki inokurudzirwa kuti ione kupararira kusati kwanyatsogadzirisa zviyero (semuenzaniso, kuenzanisa aluminium hypophosphite uye MCA). Kuti uwedzere kudzoreredza moto, funga kuwedzera 2% boron nitride nanosheets (BNNS) seyakaviri-inoshanda yekupisa conductive/flame retardant filler.
More info., pls contact lucy@taifeng-fr.com
Nguva yekutumira: Jul-01-2025
