Ukuguqulwa Kokwakhiwa Kwesikhumba se-PVC Esine-Halogen-Free Flame Retardant

Ukuguqulwa Kokwakhiwa Kwesikhumba se-PVC Esine-Halogen-Free Flame Retardant

Isingeniso

Iklayenti likhiqiza isikhumba se-PVC esinganqamuki ilangabi kanye ne-antimony trioxide eyake yasetshenziswa ngaphambilini (Sb₂O₃). Manje bahlose ukuqeda i-Sb₂O₃ futhi bashintshele kuma-flame retardants angenayo i-halogen. Ukwakhiwa kwamanje kuhlanganisa i-PVC, i-DOP, i-EPOXY, i-BZ-500, i-ST, i-HICOAT-410, ne-antimony. Ukushintsha usuka ekwakhiweni kwesikhumba se-PVC esisekelwe ku-antimony ukuya kusistimu ye-flame-retardant engenayo i-halogen kumelela ukuthuthukiswa okubalulekile kobuchwepheshe. Lolu shintsho aluhambisani kuphela nemithetho eqinile yezemvelo (isb., RoHS, REACH) kodwa futhi kuthuthukisa isithombe “sohlaza” somkhiqizo kanye nokuncintisana kwemakethe.

Izinselele Ezibalulekile

1. Ukulahleka Komphumela we-Synergistic:
   • I-Sb₂O₃ ayiyona into evimbela ilangabi eliqinile ngokwayo kodwa ibonisa imiphumela emihle kakhulu yokunqanda ilangabi nge-chlorine ku-PVC, okwenza ngcono kakhulu ukusebenza kahle. Ukususa i-antimony kudinga ukuthola enye isistimu engena-halogen ephindaphinda lokhu kusebenzisana.
2. Ukusebenza Kokubuyiswa Kwelangabi:
   • Izinqamuleli zamalangabi ezingenalo i-halogen ngokuvamile zidinga ukulayishwa okuphezulu ukuze kufinyelelwe izilinganiso ezilingana ne-flame-retardant (isb, UL94 V-0), ezingase zibe nomthelela kwizakhiwo zemishini (ukuthamba, amandla aqinile, ukunwebeka), ukusebenza kokucubungula, kanye nezindleko.
3. Izimpawu zesikhumba ze-PVC:
   • Isikhumba se-PVC sidinga ukuthamba okuhle kakhulu, ukuzwa kwesandla, ukuqedwa kwendawo (i-embossing, isicwebezelisi), ukumelana nesimo sezulu, ukumelana nokufuduka, kanye nokuguquguquka kwezinga lokushisa eliphansi. Ukwakhiwa okusha kufanele kunakekele noma kuhambisane eduze nalezi zici.
4. Icubungula ukusebenza:
   • Ukulayishwa okuphezulu kwezihlungi ezingenayo i-halogen (isb, i-ATH) kungase kuthinte ukugeleza kwencibilika nokuzinza kokucubungula.
5. Izindleko zokucatshangelwa:
   • Amanye ama-flame retardant angenawo amandla aphezulu e-halogen ayabiza, okwenza kudingeke ibhalansi phakathi kokusebenza nezindleko.

Isu lokukhetha le-Halogen-Free Flame Retardant Systems (Lesikhumba Sokwenziwa se-PVC)

1. I-Primary Flame Retardants - I-Metal Hydroxides

• I-Aluminium Trihydroxide (ATH):
  • Okuvame kakhulu, ukonga.
  • I-Mechanism: Ukubola kwe-Endothermic (~200°C), ukukhulula umhwamuko wamanzi ukuze kuncishiswe amagesi avuthayo nomoya-mpilo ngenkathi kwakhiwa ungqimba olungaphezulu oluvikelayo.
  • Okungalungi: Ukusebenza kahle okuphansi, ukulayisha okuphezulu kuyadingeka (40-70 phr), kunciphisa kakhulu ukuthamba, ukunwebeka, nokucutshungulwa; izinga lokushisa lokubola liphansi.
• I-Magnesium Hydrooxide (MDH):
  • Izinga lokushisa eliphakeme lokubola (~340°C), lilungele kangcono ukucutshungulwa kwe-PVC (160–200°C).
  • Okungalungi: Kudingeka ukulayisha okuphezulu okufanayo (40–70 phr); izindleko eziphakeme kancane kune-ATH; ingase ibe nokumunca umswakama ophezulu.

Isu:

• Uncamela i-MDH noma inhlanganisela ye-ATH/MDH (isb., 70/30) ukuze ubhalansise izindleko, ukucubungula ukuguquguquka kwezinga lokushisa, kanye nokubanda komlilo.
• Ukwelashwa okungaphezulu (isb., i-silane-coupled) i-ATH/MDH ithuthukisa ukuhambisana ne-PVC, inciphise ukucekelwa phansi kwempahla, futhi ithuthukise ukubambezeleka komlilo.

2. I-Flame Retardant Synergists

Ukuze kuncishiswe ukulayishwa okuyisisekelo kokubuyisela amalangabi nokuthuthukisa ukusebenza kahle, ama-synergists abalulekile:

• I-Phosphorus-Nitrogen Flame Retardants: Ilungele izinhlelo ze-PVC ezingenayo i-halogen.
  • I-Ammonium Polyphosphate (APP): Ithuthukisa ukushaja, yenza isendlalelo se-intumescent insulating.
    • Qaphela: Sebenzisa amamaki amelana nokushisa okuphezulu (isb., Isigaba II, >280°C) ukuze ugweme ukubola phakathi nokucubungula. Amanye ama-APP angaphazamisa ukubonakala nokungangeni kwamanzi.
  • I-Aluminium Diethylphosphinate (ADP): Isebenza kahle kakhulu, ilayisha kancane (5–20 phr), umthelela omncane ezakhiweni, ukuzinza okuhle kokushisayo.
    • I-drawback: Izindleko eziphakeme.
  • I-Phosphate Esters (isb, i-RDP, i-BDP, i-TCPP): Isebenza njengama-plasticizing retardants flame.
    • Izinzuzo: Indima ekabili (i-plasticizer + i-flame retardant).
    • Ububi: Ama-molecule amancane (isb, i-TCPP) angase afuduke/aguquke; I-RDP/BDP inokusebenza kahle kwepulasitiki okuphansi kune-DOP futhi ingase yehlise ukuguquguquka kwezinga lokushisa eliphansi.
• I-Zinc Borate (ZB):
  • Izindleko eziphansi, ezisebenza ngezindlela eziningi (i-flame retardant, intuthu, umgqugquzeli we-char, anti-dripping). Isebenzisana kahle ne-ATH/MDH kanye nezinhlelo ze-phosphorus-nitrogen. Ukulayisha okujwayelekile: 3–10 phr.
• I-Zinc Stanate/Hydroxy Stanate:
  • Izicindezeli zentuthu ezinhle kakhulu nama-synergists abushela ilangabi, ikakhulukazi kuma-polymers ane-chlorine (isb, i-PVC). Ingashintsha kancane indima ye-antimony ye-synergistic. Ukulayisha okujwayelekile: 2–8 phr.
• I-Molybdenum Compounds (isb, i-MoO₃, i-Ammonium Molybdate):
  • Izicindezelo zentuthu ezinamandla ezinokuhlanganiswa kwe-flame retardant. Ukulayisha okujwayelekile: 2–5 phr.
• I-Nano Fillers (isb, i-Nanoclay):
  • Ukulayisha okuphansi (3–8 phr) kuthuthukisa ukubambezeleka komlilo (ukwakheka kwe-char, ukuncishiswa kwezinga lokukhishwa kokushisa) kanye nezakhiwo zemishini. Ukuhlakazeka kubalulekile.

3. Izinqamuleli zentuthu

I-PVC ikhiqiza intuthu enkulu ngesikhathi sokusha. Amafomu angenayo i-halogen ngokuvamile adinga ukucindezelwa kwentuthu. I-Zinc borate, i-zinc stannate, ne-molybdenum compounds yizinqumo ezinhle kakhulu.

Ukwakhiwa Okuhlongozwayo Kwe-Halogen-Free Flame Retardant (Ngokusekelwe Ekwakhekeni Kwangempela Kwekhasimende)

Okuqondisiwe: Finyelela i-UL94 V-0 (1.6 mm noma ugqinsi) kuyilapho ugcina ukuthamba, ukucutshungulwa, kanye nezakhiwo ezibalulekile.

Okucatshangwayo:

• Ukwakhiwa kwangempela:
  • I-DOP: 50-70 phr (ipulasitiki).
  • ST: Cishe i-stearic acid (i-lubricant).
  • I-HICOAT-410: I-Ca/Zn stabilizer.
  • I-BZ-500: Cishe insiza yokuthambisa/yokucubungula (ukuqinisekisa).
  • I-EPOXY: Amafutha kabhontshisi wesoya epoxidized (co-stabilizer/plasticizer).
  • I-Antimony: Sb₂O₃ (izosuswa).

1. Uhlaka Lokwakha Olunconyiwe (nge-100 phr PVC resin)

2. Ukwakhiwa Kwesibonelo (Kudinga Ukuthuthukiswa)

Izinyathelo Ezibalulekile Zokusebenzisa

1. Qinisekisa imininingwane ye-Raw Material:
   • Cacisa ubunikazi bamakhemikhali beI-BZ-500futhiST(thintana nemininingwane yedatha yabahlinzeki).
   • Qinisekisa ukulayishwa okuqondile kweDOP,I-EPOXY, futhiI-HICOAT-410.
   • Chaza izidingo zeklayenti: Ukuncipha kwelangabi eliqondiwe (isb., ukujiya kwe-UL94), ukuthambile (ukuqina), ukusetshenziswa (izimoto, ifenisha, izikhwama?), izidingo ezikhethekile (ukumelana nokubanda, ukuzinza kwe-UV, ukumelana nokuhuzuka?), imikhawulo yezindleko.
2. Khetha Amabanga Aqondile Okubuyiswa Komlilo:
   • Cela amasampula angenawo amalangabi e-halogen enzelwe isikhumba se-PVC kubahlinzeki.
   • Beka kuqala i-ATH/MDH ephathwe phezulu ukuze uhlakazeke kangcono.
   • Ku-APP, sebenzisa amamaki amelana nokushisa okuphezulu.
   • Kuma-phosphate esters, khetha i-RDP/BDP kune-TCPP ukuze uthole ukufuduka okuphansi.
3. Ukuhlola Isikali Selebhu Nokuthuthukisa:
   • Lungiselela amaqoqo amancane anokulayisha okuhlukahlukene (isb, lungisa izilinganiso ze-MDH/APP/ZB/ZS).
   • Ukuxuba: Sebenzisa izixube ezinesivinini esikhulu (isb, i-Henschel) ukuze uhlakazeke umfaniswano. Faka uketshezi (ama-plasticizers, stabilizers) kuqala, bese kuba yizimpushana.
   • Ukucubungula Izilingo: Hlola okokusebenza kokukhiqiza (isb, i-Banbury mixer + calendering). Gada isikhathi se-plastification, i-viscosity encibilikayo, i-torque, ikhwalithi yendawo.
   • Ukuhlolwa kokusebenza:
     • Ukuncipha komlilo: UL94, LOI.
     • Izakhiwo zemishini: Ukuqina (Shore A), amandla aqinile, ubude.
     • Ukuthamba/ukuzwakala kwesandla: Isivivinyo se-subjective + sobulukhuni.
     • Ukuguquguquka kwezinga lokushisa eliphansi: Ukuhlolwa kokugoba okubandayo.
     • Ukuzinza kwe-thermal: Isivivinyo esibomvu sase-Congo.
     • Ukubukeka: Umbala, isicwebezelisi, i-embossing.
     • (Ongakukhetha) Ukuminyana kwentuthu: Igumbi lentuthu le-NBS.
4. Ukuxazulula izinkinga nokulinganisa:

5. I-Pilot & Production: Ngemva kokuthuthukisa ilebhu, yenza izivivinyo zokuhlola ukuze uqinisekise ukuzinza, ukungaguquguquki, kanye nezindleko. Khulisa kuphela ngemva kokuqinisekisa.

Isiphetho

Ukushintsha kusuka esikhumbeni se-PVC esisuselwe ku-antimony ukuya esikhumbeni se-PVC esinganqamuki ilangabi esingena-halogen kuyenzeka kodwa kudinga ukuthuthukiswa okuhlelekile. Indlela ewumongo ihlanganisa i-metal hydroxides (okungcono i-MDH efakwe phezulu), ama-synergists e-phosphorus-nitrogen (i-APP noma i-ADP), kanye nezicindezeli zentuthu ezisebenzayo (i-zinc borate, i-zinc stannate). Ngasikhathi sinye, ukuqinisa ama-plasticizers, stabilizers, lubricant, kanye nezinsiza zokucubungula kubalulekile.

Okhiye Bempumelelo:

1. Chaza okuhlosiwe okucacile nezithiyo (ukuhlehla komlilo, izakhiwo, izindleko).
2. Khetha ama-flame retardants afakazelwe angenawo ama-halogen (izihlungi eziphathwa ebusweni, i-APP yezinga eliphezulu).
3. Yenza ukuhlolwa okuqinile kwelebhu (ukuhlehla komlilo, izakhiwo, ukucubungula).
4. Qinisekisa ukuxutshwa okufanayo kanye nokuhambisana kwenqubo.

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