Formulasi tahan api referensi kanggo SK Polyester ES500 (rating UL94 V0).
I. Pendekatan Desain Formulasi
- Kompatibilitas substrat
- SK Polyester ES500: Poliester termoplastik kanthi suhu pangolahan khas 220–260°C. Flame retardant kudu tahan kisaran suhu iki.
- Persyaratan Utama: Balance flame retardancy (V0), sifat mekanik (tensile/impact strength), lan fluiditas pangolahan.
- Synergistic Flame Retardant System
- Ultrafine Aluminium Hydroxide (ATH): Tahan api primer, dehidrasi endotermik. Loading kudu ngimbangi retardansi geni lan sifat mekanik.
- Aluminium Hypophosphite: Char-forming synergist, dianggo karo ATH kanggo nggawe efek sinergis fosfor-aluminium, nambah kualitas char.
- Seng Borate: Char enhancer, suppresses asap, lan mbentuk alangi kandhel karo ATH.
- MCA (Melamine Cyanurate): Gas-phase flame retardant, dilutes oksigen lan nyegah leleh netes.
II. Formulasi sing Disaranake (Persentase Bobot)
| Komponen | rasio | Cathetan pangolahan |
|---|---|---|
| SK Polyester ES500 | 45–50% | resin dhasar; pilih kelas cairan dhuwur kanggo ngimbangi viskositas pengisi. |
| Ultrafine ATH | 25–30% | Lumahing-dimodifikasi karo agen kopling silane (KH-550), D50 <3 μm. |
| Aluminium Hypophosphite | 10–12% | Tahan panas (>300°C), wis dicampur karo ATH lan ditambahake kanthi bertahap. |
| Seng Borat | 6–8% | Ditambahake karo MCA kanggo ngindhari karusakan struktural geser dhuwur. |
| MCA | 4–5% | Suhu proses <250°C, dispersi kacepetan kurang. |
| Dispersant | 2–3% | Dispersant sing cocog karo poliester (contone, BYK-161) + komposit lilin polietilena. |
| Agen Kopling (KH-550) | 1% | Pre-treat ATH lan aluminium hypophosphite; kecemplung etanol banjur dikeringake. |
| Agen Anti-Dripping | 0,5–1% | PTFE micropowder kanggo nyuda kontak leleh. |
| Bantuan Pangolahan | 0,5% | Seng stearate (lubrication lan anti-stick). |
III. Kontrol Proses Kunci
- Optimization dispersi
- Pra-perawatan: Rendhem ATH lan aluminium hypophosphite ing larutan etanol KH-550 1% suwene 2 jam, banjur garing ing 80°C.
- Urutan Campuran:
- Base resin + dispersant + coupling agent → Low-speed mixing (500 rpm, 5 min).
- Tambah modifikasi ATH/aluminium hypophosphite → High-speed shear (2500 rpm, 20 min).
- Tambah seng borat/MCA/PTFE → Low-speed mixing (800 rpm, 10 min).
- Peralatan: Twin-screw extruder (zona suhu: zona feed 200 ° C, zona leleh 230 ° C, mati 220 ° C).
- Ngolah Kontrol Suhu
- Priksa manawa suhu leleh <250°C kanggo nyegah dekomposisi MCA (MCA decomposes ing 250–300°C).
- Pelet sing adhem banyu sawise ekstrusi kanggo nyegah migrasi tahan api.
IV. Mekanisme Sinergis Flame Retardant
- ATH + Aluminium Hypophosphite
- ATH nyerep panas lan ngeculake uap banyu, ngencerake gas sing gampang kobong.
- Aluminium hypophosphite catalyzes tatanan char kandhel (AlPO₄), ngalangi transfer panas.
- Seng Borate + MCA
- Seng borat mbentuk penghalang kaca liwat retakan arang.
- MCA decomposes kanggo ngeculake NH₃, ngencerake oksigen lan nyegah reaksi radikal bebas.
- PTFE Anti-Dripping
- micropowder PTFE mbentuk jaringan fibrous, ngurangi risiko kontak leleh-netes.
V. Performance Tuning & Troubleshooting
| Jeksa Agung bisa ngetokake umum | Solusi |
|---|---|
| Retardancy geni ngisor V0 (V1/V2) | Tambah hypophosphite aluminium kanggo 12% + MCA kanggo 5%, utawa nambah 2% encapsulated fosfor abang (synergistic karo aluminium hypophosphite). |
| Sifat mekanik suda | Kurangi ATH dadi 25%, tambahake 5% serat kaca (reinforcement) utawa 3% maleic anhydride-grafted POE (toughening). |
| Fluiditas pangolahan sing ora apik | Tambah dispersant kanggo 3%, utawa nambah 0,5% low-MW polyethylene wax (lubrication). |
| Lumahing mekar | Ngoptimalake dosis agen kopling utawa ngalih menyang agen kopling titanate (NDZ-201) kanggo ikatan antarmuka sing luwih apik. |
VI. Metrik Validasi
- Tes UL94 V0:
- Spesimen 1,6 mm lan 3,2 mm, total wektu ngobong < 50 detik sawise rong kontak, ora netes kontak.
- LOI: Target ≥30% (aktual ≥28%).
- Sifat Mekanik:
- Kekuatan tarik > 40 MPa, kekuatan impact > 5 kJ/m² (standar ASTM).
- Stabilitas termal (TGA):
- Sisa char ing 800°C > 20%, suhu dekomposisi awal > 300°C.
VII. Rumus Rujukan Tuladha
| Komponen | Isi (%) |
|---|---|
| SK Polyester ES500 | 48% |
| Ultrafine ATH (dimodifikasi) | 28% |
| Aluminium Hypophosphite | 11% |
| Seng Borat | 7% |
| MCA | 4% |
| BYK-161 Dispersant | 2,5% |
| Agen Kopling KH-550 | 1% |
| Agen Anti-Dripping PTFE | 0,8% |
| Seng Stearat | 0,5% |
Desain formulasi lan proses iki kanthi efektif entuk retardasi nyala UL94 V0 kanggo SK Polyester ES500 nalika ngimbangi kemampuan proses lan sifat mekanik. Uji coba skala cilik dianjurake kanggo verifikasi sawur sadurunge rasio fine-tuning (contone, imbangan aluminium hypophosphite lan MCA). Kanggo nambah retardancy geni luwih, nimbang nambah 2% boron nitride nanosheets (BNNS) minangka dual-fungsi konduktif termal / ngisi retardant geni.
More info., pls contact lucy@taifeng-fr.com
Wektu kirim: Jul-01-2025
