Overview of Exolit Flame retardants in thermoset applications

Transcription

1 Overview of Exolit Flame retardants in thermoset applications Dr. Frank Osterod TM & Development BL Flame Retardants

2 2 Applications for thermosets and composites

3 3 Product groups and chemistry Base Materials / Resins Unsaturated polyester resins Epoxy resins Phenolic resins Polyurethane resins Polyurethane foams (rigid and flexible) Exolit AP Flame Retardants - FR based on Ammonium polyphosphate Exolit OP - FR based on Organophosphorus Exolit RP - FR based on Red phosphorus

4 4 Detailed Exolit product overview for thermosets (1/2) Exolit AP - Exolit AP 422 Ammonium polyphosphate - Exolit AP 423 Ammonium polyphosphate, small particles - Exolit AP 462 Ammonium polyphosphate, coated surface - Exolit AP 740 Intumescent system with ammonium polyphosphate - Exolit AP 742 Intumescent system with ammonium polyphosphate - Exolit AP 740 S&F Intumescent system with ammonium polyphosphate - Exolit AP 750 Intumescent system with ammonium polyphosphate

5 5 Detailed Exolit product overview for thermosets (2/2) Exolit OP - Exolit OP 1230 Al-salt, organo-phosphorus - Exolit OP 930 / 935 Al-salt, organo-phosphorus - Exolit OP 550 organo-phosphorus, reactive - Exolit OP 560 organo-phosphorus, reactive, (requires end user declaration) Exolit RP - Exolit RP 6500 Red phosphorus with epoxy resin carrier - Exolit RP 6520 Red phosphorus with castor oil Special products - PU 6580 Red phosphorus in TCPP

6 6 Fire standards for thermoset applications Examples ISO 5658 (IMO Version) Flame spread UL 94 V0, mainly used for electronic components ISO Cone Calorimeter, heat release rate (HRR) and MAHRE Smoke density ISO 5659, measurement with optical system

7 International UL 94 (V0) Specimen Burner Cotton electronics applications specimen: 5 specimen: 12,7 x 127 mm test: gas burner 2 intervals á 10 s flaming classification: total flaming (1) V0 < 10 s total flaming (5) V0 < 50 s flaming dripping V0 = no dripping with flame retardant class: V0, V1, V2 without flame retardant

8 8 Some examples to see how complex the world of flame retardant tests can be: Some examples from mass transit (Railway) FR tests in Europe: Old system classification Germany DIN 5510 Italy UNI CEI France NF F Spain RENFE DT PCI 5A Great Britain BS USA NFPA 130 New system European regulation EN :2013 With 4 main test: Spread of flame ISO Heat release rate ISO Smoke density and smoke toxicity ISO Hazard level HL1, HL2, HL3

9 9 Rolling stock EU standard: prcen TS Set No. R1= interior components, horizontal downwards facing surfaces, upwards facing within cavities, electrical hood Gelcoat 100 phr AP phr AP phr AP 740 Laminat 50 phr ATH 125 phr ATH 100 phr AP 740 ISO CFE HL3 HL3 HL3 ISO CIT HL3 HL3 HL3 ISO VOF4 / Ds4 HL2 HL3 HL2 ISO MAHRE HL3 HL3 HL1

10 10 Exolit AP - Intumescent Systems for UP-resins Exolit AP 740 Exolit AP 742 Principle of Intumescence: layers of charred foam protects laminate laminate

11 11 Exolit FRs in UP resins under different test conditions

12 12 Exolit FRs in EP resins under UL 94 test conditions

13 13 Polyurethanes Different types and applications Raw materials Flexible polyether foams Flexible polyester foams Rigid foams Cast resins Coatings Polyols Isocyanate Amine catalysts Silicone stabilizers Flame retardants (Exolit AP 422, Exolit OP 550 or OP 560) Blowing agents

14 14 Product range for PUR foams Exolit OP 550 liquid, reactive flame retardant Exolit OP 560 liquid, reactive flame retardant Both products are liquid and can be used with conventional equipment Functionality approx. 2 For Exolit OP 560 an end user declaration is necessary Prefered products for flexible foams Exolit AP 422 white powder, additive flame retardant Prefered product for rigid foams DIN 4102 B2 formulations available

15 15 Flexible Polyether Foam FMVSS 302, class SE California TB 117 Border conentration for achieving [php] ,5 25,0 27,5 30,0 32,5 35,0 density [kg/m³] 25,0 30,0 35,0 density [kg/m³] TDCPP Exolit OP 550 Exolit OP 560

16 16 Exolit Flame Retardants in case of fire: - low smoke gas corrosivity (reduced damage) - low smoke density (extended escape time) compatibility: - highly effective (low dosage, good mechanics) - no migration - good recyclability in final product: - excellent ageing stability (high quality during life time) - attractive price/performance ratio