High‐efficiency ammonium polyphosphate intumescent encapsulated polypropylene flame retardant

Integration of N- and P- elements in sodium alginate aerogels for efficient flame retardant and thermal insulating properties

In the field of building energy conservation, the development of biodegradable biomass aerogels with excellent mechanical performance, flame retardancy and thermal insulation properties is of particular importance. Here, a directional freeze-drying method was used for fabricating composite sodium alginate (SA) aerogels containing functionalized ammonium polyphosphate (APP) flame retardant. In particular, APP was coated with melamine (MEL) and phytic acid (PA) by a supramolecular assembly process. Through optimizing the flame retardant addition, the SA-20 AMP sample exhibited excellent flame retardant and thermal insulation properties, with the limiting oxygen index of 38.2 % and the UL-94 rating of V-0. Such aerogels with anisotropic morphology demonstrated a low thermal conductivity of 0.0288 (W/m·K) in the radial direction (perpendicular to the lamellar structure). In addition, as-obtained aerogels displayed remarkable water stability and mechanical properties, indicating significant potential for practical applications.

A novel P/N/Si/Zn-containing hybrid flame retardant for enhancing flame retardancy and smoke suppression of epoxy resins

Currently, additively efficient flame retardants are being developed to enhance the smoke suppression, flame retardancy, and thermal properties of composite materials. To this end, the current study designed and prepared a novel P/N/Si/Zn-containing organic-inorganic hybrid denoted as APHZ. Its inorganic part was 2-methylimidazole zinc salt (ZIF-8), which improved its smoke suppression and catalytic carbonization. The organic part (P/N/Si-containing compound) promoted its flame retardancy and interfacial compatibility between APHZ and epoxy resin (EP). The test results revealed that EP/APHZ-3 composites achieved a V-0 rating and a notable LOI value of 30.7% when introducing 3 wt% APHZ into the EP matrix. Cone calorimetry tests (CCT) further demonstrated that the average heat release rate (av-HRR), total smoke production (TSP), and CO production (COP) of EP/APHZ-3 were reduced by 23.3%, 14.0%, and 21.1%, respectively. Meanwhile, the char residual was increased by 60.6%, as compared to pure EP. Furthermore, the flame-retardant mechanism of EP/APHZ composites was investigated by the XPS, TG-FTIR, and Raman spectroscopy techniques. The observed synergistic effect of the imidazole skeleton ZIF-8 and P/N/Si-containing compound in APHZ facilitated the generation of a dense multi-element char layer, with the condensed phase flame-retardant mechanism playing a dominant role. These findings contribute to developing and designing high-performance flame-retardant EP.

Effects of Processing Conditions on the Properties of Monoammonium Phosphate Microcapsules with Melamine-Formaldehyde Resin Shell

To develop monoammonium phosphate (MAP) as a novel acid source for durable intumescent fire retardants (IFR), MAP microcapsules (MCMAPs) containing MAP as the internal core and melamine-formaldehyde (MF) as the external shell were prepared by in situ polymerization in this study. The influences of synthesis conditions (including reaction temperature, polymerization time, and reaction pH value) on the properties of obtained MCMAPs (MAP content, yield, morphologies, and thermal properties) were then investigated systematically. The morphologies, chemical structures, and thermal properties were characterized by optical microscopy, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), Fourier transform infrared (FTIR) spectroscopy, and thermogravimetry analyzer (TGA). The results show that MAP was well encapsulated by MF resin. No microcapsules are obtained at <55 °C or with polymerization times <1 h. Optimal preparation conditions of reaction temperature, polymerization time, and reaction pH value are 75 °C, 3 h, and 5.5, respectively. Those results provide process reference and theoretical basis for preparing MCMAPs and could promote the application of MAP microcapsules in wood flame-retardant materials.

Preparation of Naphthalene-Based Flame Retardant for High Fire Safety and Smoke Suppression of Epoxy Resin

One of the current challenges in the development of flame retardants is the preparation of an environmentally friendly multi-element synergistic flame retardant to improve the flame retardancy, mechanical performance, and thermal performance of composites. This study synthesized an organic flame retardant (APH) using (3-aminopropyl) triethoxysilane (KH-550), 1,4-phthalaadehyde, 1,5-diaminonaphthalene, and 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) as raw materials, through the Kabachnik-Fields reaction. Adding APH to epoxy resin (EP) composites could greatly improve their flame retardancy. For instance, UL-94 with 4 wt% APH/EP reached the V-0 rating and had an LOI as high as 31.2%. Additionally, the peak heat release rate (PHRR), average heat release rate (AvHRR), total heat release (THR), and total smoke produced (TSP) of 4% APH/EP were 34.1%, 31.8%, 15.2%, and 38.4% lower than EP, respectively. The addition of APH improved the mechanical performance and thermal performance of the composites. After adding 1% APH, the impact strength increased by 15.0%, which was attributed to the good compatibility between APH and EP. The TG and DSC analyses revealed that the APH/EP composites that incorporated rigid naphthalene ring groups had higher glass transition temperatures (Tg) and a higher amount of char residue (C₇₀₀). The pyrolysis products of APH/EP were systematically investigated, and the results revealed that flame retardancy of APH was realized by the condensed-phase mechanism. APH has good compatibility with EP, excellent thermal performance, enhanced mechanical performance and rational flame retardancy, and the combustion products of the as-prepared composites complied with the green and environmental protection standards which are also broadly applied in industry.

Dual-functional marine algal carbon-based materials with highly efficient dye removal and disinfection control

The design and simple, green preparation of dual-functional materials for the decontamination of both hazardous dyes and pathogenic microorganisms from wastewater remain challenging currently. Herein, a promising marine algal carbon-based material (named C-SA/SP) with both highly efficient dye adsorptive and antibacterial properties was fabricated based on the incorporation of sodium alginate and a low dose of silver phosphate via a facile and eco-friendly approach. The structure, removal of malachite green (MG) and congo red (CR), and their antibacterial performance were studied, and the adsorption mechanism was further interpreted by the statistical physics models, besides the classic models. The results show that the maximum simulated adsorption capacity for MG reached 2798.27 mg/g, and its minimal inhibit concentration for Escherichia coli (E. coli) and Staphylococcus aureus (S. aureus) was 0.4 mg/mL and 0.2 mg/mL, respectively. The mechanistic study suggests that silver phosphate exerted the effects of catalytic carbon formation and pore formation, while reducing the electronegativity of the material as well, thus improving its dye adsorptive performance. Moreover, the MG adsorption onto C-SA/SP showed vertical orientation and a multi-molecular way, and its adsorption sites were involved in the adsorption process with the increase of temperature. Overall, the study indicates that the as-made dual-functional materials have good applied prospects for water remediation.

Flame Retardancy of Nylon 6 Fibers: A Review

As synthetic fibers with superior performances, nylon 6 fibers are widely used in many fields. Due to the potential fire hazard caused by flammability, the study of the flame retardancy of nylon 6 fibers has been attracting more and more attention. The review has summarized the present research status of flame-retarded nylon 6 fibers from three aspects: intrinsic flame-retarded nylon 6, nylon 6 composites, and surface strategies of nylon 6 fibers/fabrics. The current main focus is still how to balance the application performances, flame retardancy, and production cost. Moreover, melt dripping during combustion remains a key challenge for nylon 6 fibers, and the further developing trend is to study novel flame retardants and new flame-retardancy technologies for nylon 6 fibers.

Synergistic Effect of Activated Carbon, NiO and Al2O3 on Improving the Thermal Stability and Flame Retardancy of Polypropylene Composites

It is difficult to enhance the char yields of polypropylene (PP) due to the preferential complete combustion. Successful formation of abundant char layer structure of PP upon flammability was obtained due to the synergistic effect of NiO, Al₂O₃ and activated carbon (AC). From characterization of scanning electron microscopy (SEM) and transmission electron microscopy (TEM), it was revealed that the microstructure of residual char contained large amount of carbon nanotubes. Compared to the modification of AC, NiO and Al₂O₃ alone, the combination of AC, NiO and Al₂O₃ dramatically promotes the charring ability of PP. In the case of AC and NiO, NiO plays a role of dehydrogenation, resulting in the degradation product, while AC mainly acts as carbonization promoter. The addition of Al₂O₃ results in higher dispersion and smaller particle size of NiO, leading to greater exposure of active sites of NiO and higher dehydrogenation and carbonization activity. Compared to the neat PP, the decomposition temperature of the PP modified by combined AC, NiO and Al₂O₃ was increased by 90 ℃. The yield of residual char of AC-5Ni-Al-PP reached as high as 44.6%. From the cone calorimeter test, the heat release rate per unit area (HRR) and total heat release per unit area (THR) of PP composite follows the order AC-5Ni-Al-PP < AC-10Ni-Al-PP < AC-Ni-PP < AC-15Ni-Al-PP < AC-1Ni-Al-PP. Compared to the neat PP, the peak of HRR declined by 73.8%, 72.7%, 71.3%, 67.6% and 62.5%, respectively.

Simultaneously Enhancing the Flame Retardancy, Water Resistance, and Mechanical Properties of Flame-Retardant Polypropylene via a Linear Vinyl Polysiloxane-Coated Ammonium Polyphosphate

It is challenging to improve the water resistance, flame retardancy, mechanical performance, and balance of halogen-free flame-retardant polypropylene (PP) composites. For this purpose, a linear vinyl polysiloxane (PD) was synthesized and then self-crosslinked under benzoyl peroxide to prepare surface-coated ammonium polyphosphate (APP@PD). Apparently, this linear vinyl polysiloxane self-crosslinking coating strategy was completely different from the commonly used sol-gel-coated APP with silane monomers. After coating, the water contact angles (WCA) of APP and APP@PD were 26.8° and 111.7°, respectively, showing high hydrophobicity. More importantly, PP/APP@PD/dipentaerythritol (DPER) showed a higher limiting oxygen index (LOI) and better UL-94 V-0 rate in comparison with PP/APP/DPER composites. After water immersion at 70 °C for 168 h, only PP/APP@PD/DPER kept the UL-94 V-0 rate and lowered the deterioration of the LOI, reflecting the better water-resistance property of APP@PD. Consistently, the cone calorimeter test results displayed a 26.2% and 16.7% reduction in peak heat release rate (PHRR) and total smoke production (TSP), respectively. Meanwhile, the time to peak smoke production rate (T_PSPR) increased by 90.2%. The interfacial free energy (IFE) between APP@PD and PP was calculated to evaluate the interfacial interaction between PP and APP@PD. A reduction of 84.2% in the IFE between APP@PD and PP is responsible for the improvement in compatibility and the increase in flame retardancy, water resistance, and mechanical properties of the composites.

Research and Application of Biomass-Based Wood Flame Retardants: A Review

Wood is widely used as a construction material due to its many advantages, such as good mechanical properties, low production costs, and renewability. However, its flammability limits its use in construction. To solve the problem of wood flammability, the most common method to improve the fire safety of wood is to modify the wood by deep impregnation or surface coating with flame retardants. Therefore, many researchers have found that environmentally friendly and low-cost biomass materials can be used as a source of green flame retardants. Two aspects of biomass-based intumescent flame retardants are summarized in this paper. On the one hand, biomass is used as one of the three sources or as a flame-retardant synergist in combination with other flame retardants, which are called composite biomass intumescent flame retardants. On the other hand, biomass is used alone as a feedstock to produce all-biomass intumescent flame retardants. In addition, the potential of biomass-based materials as an environmentally friendly and low-cost FR source to produce high-performance biomass-based flame retardants with improved technology was also discussed in detail. The development of biomass-based intumescent flame retardants represents a viable and promising approach for the efficient and environmentally friendly production of biomass-based flame retardants.

Magnesium hydroxide coated hollow glass microspheres/chitosan composite aerogels with excellent thermal insulation and flame retardancy

The development of an environmental-friendly thermal insulation and flame retardant material has attracted widespread attention in modern architecture. In this work, a kind of novel aerogel composites were prepared by incorporation of Mg(OH)₂ coated hollow glass microspheres (HGM) into chitosan (CSA) matrix and then cross-linking by glutaraldehyde (abbreviated as CSA-HGM-Mg(OH)₂). The as-prepared composite aerogel exhibits vertical directional channel with high porosity and excellent thermal insulation with a low thermal conductivity of 0.035 W m^-1 k^-1. Besides, it shows excellent flame retardancy with a high limit oxygen index (LOI) value up to 50.8, which is one of the highest values among the most of flame retardants reported previously. Also, a very low peak heat release rate (pHRR) of 24.12 kW m^-2 was obtained which makes the aerogel composite reaching UL-94 V-0 rating. Such results may be attributed to a synergy effect by combination of its abundantly porous structure derived from HGM to give a better thermal insulation and excellent nonflammability of CSA and Mg(OH)₂ to offer a superior flame retardancy. Taking advantages of its high mechanical strength, low cost materials, simple and scalable preparation method, CSA-HGM-Mg(OH)₂ aerogel composites may hold great potential for future thermal insulation and flame retardant applications.

The Re2Sn2O7 (Re = Nd, Sm, Gd) on the enhancement of fire safety and physical performance of Polyolefin/IFR cable materials

Polyolefin (PO) cables used in confined spaces need to have low smoke, low heat release, low toxic gas release and excellent physical properties. In this work, a series of rare earth stannates Re₂Sn₂O₇ (RES, Re = Nd, Sm, Gd) with high temperature catalytic performance were prepared by hydrothermal method for synergistic flame retardant PO/IFR. The flame retardancy, heat release, smoke density, toxic gas release and physical properties of PO composites were thoroughly studied in detail. The RES could enhance the vertical burning rating and the limiting oxygen index (LOI) of PO/IFR composites. Moreover, the residual char of the thermogravimetric analysis increased from 9.7% to 11.4 wt% after the RES added in PO/IFR system. Interestingly, the PO/IFR system containing Gd₂Sn₂O₇ exhibits the lowest peak heat release rate of 233.7 kW/m². Excellent flame resistance due to the formation of a complete and compact protective char layer. In addition, the toxic release of PO during combustion is also effectively reduced by introducing the RES. The tube furnace combustion test shows that the emission of carbon oxide (CO) and hydrogen cyanide (HCN) of PO/IFR/Gd₂Sn₂O₇ are the lowest. It can be attributed to the catalytic effect of rare earth elements and the blocking effect of the dense char layer. In addition, compared with the PO/IFR composites, the PO/IFR/RES system demonstrate higher mechanical properties and volume resistivity. Therefore, the addition of RES has a positive effect on improving the physical properties and fire safety properties of the PO/IFR cable composites, especially suitable for using in confined spaces.

Synergistic Flame Retardant Effect of Barium Phytate and Intumescent Flame Retardant for Epoxy Resin

Recently, widespread concern has been aroused on environmentally friendly materials. In this article, barium phytate (Pa-Ba) was prepared by the reaction of phytic acid with barium carbonate in deionized water, which was used to blend with intumescent flame retardant (IFR) as a flame retardant and was added to epoxy resin (EP). Afterward, the chemical structure and thermal stability of Pa-Ba were characterized by Fourier transform infrared (FTIR) spectroscopy and thermogravimetric analysis (TGA), respectively. On this basis, the flammability and flame retardancy of EP composites were researched. It is shown that EP/14IFR/2Ba composite has the highest limiting oxygen index (LOI) value of 30.7%. Moreover, the peak heat release rate (PHRR) of EP/14IFR/2Ba decreases by 69.13% compared with pure EP. SEM and Raman spectra reveal the carbonization quality of EP/14IFR/2Ba is better than that of other composites. The results prove that Pa-Ba can cooperate with IFR to improve the flame retardancy of EP, reducing the addition amount of IFR in EP, thus expanding the application range of EP. In conclusion, adding Pa-Ba to IFR is a more environmentally friendly and efficient method compared with others.

Preparation of flame-retardant, hydrophobic, ultraviolet protective, and luminescent transparent wood

Transparent wood with multifunctional properties has recently attracted more attention as an efficient building product. Here, we describe the development of transparent wood with long-persistent phosphorescence, tough surface, high durability, photostability, and reversibility without fatigue, and with ultraviolet shielding, superhydrophobicity, and flame-retardant activity. This long-persistent phosphorescent, or glow-in-the-dark, smart wood exhibited an ability to continue emitting light for prolonged periods of time. The photoluminescent translucent wooden substrate was prepared by immobilizing lignin-modulated wooden bulk with an admixture of methylmethacrylate (MMA), ammonium polyphosphate (APP), and lanthanide-doped strontium aluminate (LSA; SrAl₂ O₄ :Eu²⁺ ,Dy³⁺ ) phosphor nanoparticles. The photoluminescent transparent wood displayed a colour switch from colourless to bright white beneath ultraviolet (UV) light and greenish-yellow in the dark as reported by Commission Internationale de l'Éclairage laboratory colorimetric space coordinates. The generated phosphorescent wooden substrates demonstrated an absorbance band at 365 nm and an emission band at 516 nm. The phosphorescent transparent wood was improved flame-retardant properties, ultraviolet shielding, and superhydrophobic properties, as well as a reversible long-persistent phosphorescent responsiveness to UV light without fatigue. The current approach demonstrated a potential large-scale production strategy for multifunctional transparent wooden substrates for a range of applications such as smart windows, gentle indoor and outdoor lighting, and safety directional signs in buildings.