A combination of POSS and polyphosphazene for reducing fire hazards of epoxy resin

Biomass-derived polyphosphazene toward simultaneously enhancing the flame retardancy and mechanical properties of epoxy resins

As one of the most widely used polymers, the intrinsic brittleness and high flammability bring about a stringent requirement for the practical application of epoxy resins (EPs). It is difficult to toughen EP without compromising its mechanical and thermal properties for many conventional toughening agents. Here, a novel furan-derived bio-based polyphosphazene (PFMP) with a flexible backbone and rigid side groups was prepared by the nucleophilic substitution reaction between polydichlorophosphazene (PDCP) and furfuralcohol. The resultant PFMP was incorporated into EP to realize exceptional toughening, strengthening, and flame retardant function. By adding 15% of PFMP, the limit oxygen index value is from 25% (EP) to 33% (EP/PFMP-15) and reaches the UL-94 V-0 rating. According to the cone calorimeter results, EP/PFMP-15 exhibits exceedingly reduced peak heat release rate (pHRR) (50.2%) and total heat release (THR) (49.6%). The significantly increased fire performance index (FPI) and decreased fire growth rate index (FIGRA) of EP/PFMP-15 demonstrate an improvement in its flame retardancy. The catalytic carbonization effect (condensed phase) and radical quenching effect (gas phase) of PFMP account for the greatly improved flame retardancy. Moreover, the impact and tensile tests indicate that PFMP can ameliorate the mechanical performance of EP with a maximum increase of impact strength (111.8%) and elongation at break (35.2%) for EP/PFMP-5. With 15% PFMP added, the tensile strength of EP/PFMP-15 increases by 40.4%. This work demonstrates that PFMP is expected to overcome shortcomings (flammability, toughness, and strength) of EP and spread its applied fields.

Organic-Inorganic Modification of Magnesium Borate Rod by Layered Double Hydroxide and 3-Aminopropyltriethoxysilane and Its Effect on the Properties of Epoxy Resin

To alleviate the safety hazards associated with the use of epoxy resin (EP), a multifunctional filler was designed. This study firstly combines the superior mechanical properties of magnesium borate rods (MBR) with the excellent smoke suppression and flame-retardant characteristics of layered double hydroxide (LDH). H₂PO₄^- intercalated LDH (LDHP) was coated on the MBR surface to obtain inorganic composite particles MBR@LDHP. Subsequently, MBR@LDHP was modified with 3-aminopropyltriethoxysilane (APES) to obtain organic-inorganic composite particles MBR@LDHP-APES. Eventually, the hybrid particles were added to EP to prepare the composite materials. Thereafter, the morphology, composition, and structure of MBR@LDHP-APES were characterized utilizing scanning electron microscopy (SEM), Fourier transform infrared (FTIR), and X-ray diffraction (XRD). The results indicated the successful preparation of MBR@LDHP-APES, after which we investigated the effects of MBR@LDHP-APES on the smoke suppression, flame retardancy, and mechanical characteristics of EP. As observed, the EP composites containing 7.5 wt% MBR@LDHP-APES exhibited superior smoke suppression and flame retardancy abilities. The limiting oxygen index reached 33.5%, which is 36.73% greater than pure EP, and the lowest values of total heat and smoke release were observed for the composite materials. In addition, the mechanical properties test revealed that MBR@LDHP-APES considerably enhanced the tensile strength as well as the flexural strength of the composites. Furthermore, mechanistic studies suggested that the barrier effect of MBR, endothermic decomposition of LDHP, and the synergistic effect of LDHP and APES contributed essentially to the smoke suppression and flame-retardant properties of the material. The findings of this research point to a potential method for enhancing the EP's ability to suppress smoke and flames while enhancing its mechanical properties.

High performance flame-retardant organic-inorganic hybrid epoxy composites with POSS and DOPO-based co-curing agent

Polyhedral oligomeric silsesquioxane (POSS) and a highly effective 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO)-based flame retardant co-curing agent (D-bp) were chemically introduced into the 4,4′-diaminodiphenyl methane (DDM)/diglycidyl ether of bisphenol A (DGEBA) epoxy system to create organic–inorganic hybrid epoxy composites with simultaneously improved flame retardancy and mechanical properties. The results revealed that POSS/D-bp/DGEBA hybrid composites exhibited excellent comprehensive performance, in which the V-0 criterion of the UL-94 test was passed and the peak of heat release rate (P-HRR) was significantly decreased from 939 to 371 kW m⁻² when the phosphorus content was only 0.25 wt%. The glass transition temperature (T_g) increased by 16.2 °C and obvious improvement in the mechanical properties was also evidenced.

This paper introduces flame-retardant organic–inorganic hybrid epoxy composites possessing excellent comprehensive performance, which results from the phosphorus–silicon synergistic flame retardant effect of the glycidyl POSS and DOPO derivative.

A cross-linked charring strategy for mitigating the hazards of smoke and heat of aluminum diethylphosphonate/polyamide 6 by caged octaphenyl polyhedral oligomeric silsesquioxanes

Aluminum diethylphosphonate (ADP) is a highly efficient phosphorus-based flame retardant, widely used in polyamide 6 (PA6). However, ADP/PA6 releases large amounts of heat and smoke under high heat flux, which commonly means serious hazards to life and property. Octaphenyl polyhedral oligomeric silsesquioxanes (OPS) is an organic-inorganic hybrid silicon compound, playing flame retardant role in condensed phase. In this work, combustion behaviors of OPS/ADP/PA6 were investigated by limited oxygen index (LOI), UL94 and cone calorimeter (CONE) tests. The LOI and UL94 rating results did not change obviously, while the CONE data and smoke density data showed the synergistic effect of OPS and ADP in PA6. For 2.5%OPS/7.5%ADP/PA6, the peak values of heat, smoke and CO release rate (pk-HRR, pk-RSR, D_s, max with/without pilot flame and pk-COP) decreased by 60.2%, 82.1%, 45.9%/38.3% and 80.4% respectively, compared with 10%ADP/PA6. Moreover, 2.5%OPS/7.5%ADP/PA6 produced 337.5% more residue than 10%ADP/PA6. TGA, TG-IR, SEM-EDS, XPS and py-GC/MS were used to further explore the synergistic mechanism of OPS and ADP. It was verified that the cross-linked charring strategy apparently has weakened the hazards of smoke and heat of PA6. This work proposed a possible technical approach to solve both fire risk and heat/smoke hazards of PA6.

Preparation of Room Temperature Vulcanized Silicone Rubber Foam with Excellent Flame Retardancy

To retard the spread of fire in many cases with sealing materials is significant. A series of silicone rubber foam materials were prepared with room temperature vulcanization and foaming reactions. The morphology, chemical structure, cell structure, and thermal stability were investigated and results proved that the synthesis of silicone rubber was successful in a wide range of feed ratios. The fire-retardant tests were carried out to study the fire-proof property of the composite materials, and the excellent performance showed a promising prospect for wide application in sealing materials.

Synergistic Effects of Ladder and Cage Structured Phosphorus-Containing POSS with Tetrabutyl Titanate on Flame Retardancy of Vinyl Epoxy Resins

The cage and ladder structured phosphorus-containing polyhedral oligomeric silsesquioxanes (DOPO-POSS) have been synthesized through the hydrolytic condensation of 9,10-dihydro-9-oxa-10-phosphenanthrene-10-oxide (DOPO)-vinyl triethoxysilane (VTES). The unique ladder and cage–ladder structured components in DOPO-POSS endowed it with good solubility in vinyl epoxy resin (VE), and it was used with tetrabutyl titanate (TBT) to construct a phosphorus-silicon-titanium synergy system for the flame retardation of VE. Thermal stabilities, mechanical properties, and flame retardancy of the resultant VE composites were investigated by thermal gravimetric analysis (TGA), dynamic mechanical analysis (DMA), three-point bending tests, limiting oxygen index (LOI) measurement, and cone calorimetry. The experimental results showed that with the addition of only 4 wt% DOPO-POSS and 0.5 wt% TBT, the limiting oxygen index value (LOI) increased from 19.5 of pure VE to 24.2. With the addition of DOPO-POSS and TBT, the peak heat release rate (PHRR), total heat release (THR), smoke production rate (SPR), and total smoke production (TSP) were decreased significantly compared to VE-0. In addition, the VE composites showed improved thermal stabilities and mechanical properties comparable to that of the VE-0. The investigations on pyrolysis volatiles of cured VE further revealed that DOPO-POSS and TBT exerted flame retardant effects in gas phase. The results of char residue of the VE composites by SEM and XPS showed that TBT and DOPO-POSS can accelerate the char formation during the combustion, forming an interior char layer with the honeycomb cavity structure and dense exterior char layer, making the char strong with the formation of Si-O-Ti and Ti-O-P structures.

Effect of Cyclotriphosphazene-Based Curing Agents on the Flame Resistance of Epoxy Resins

Epoxy resins are characterized by excellent properties such as chemical resistance, shape stability, hardness and heat resistance, but they present low flame resistance. In this work, the synthesized derivatives, namely hexacyclohexylamino-cyclotriphosphazene (HCACTP) and novel diaminotetracyclohexylamino-cyclotriphosphazene (DTCATP), were applied as curing agents for halogen-free flame retarding epoxy materials. The thermal properties and combustion behavior of the cured epoxy resins were investigated. The obtained results revealed that the application of both derivatives significantly increased flame resistance. The epoxy resins cured with HCACTP and DTCATP exhibited lower total heat release together with lower total smoke production compared to the epoxy materials based on conventional curing agents (dipropylenetriamine and ethylenediamine). Comparing both derivatives, the HCACTP-cured epoxy resin was found to provide a higher flame resistance. The designed novel class of epoxy materials may be used for the preparation of materials with improved flame resistance properties in terms of flame spreading and smoke inhibition.

Phosphorus-Containing Silsesquioxane Derivatives as Additive or Reactive Components of Epoxy Resins

Two phosphorus-containing cage-like silsesquioxane derivatives were synthesized as reactive or additive flame retardants for epoxy resin. The silsesquioxanes were obtained via an epoxide ring-opening reaction using a 10-hydroxy-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPA). In one derivative containing in its structure 4 glycidoxypropyl and 4 phosphate groups, denoted as 4P4GS, only half of the epoxy rings was reacted with phosphate to obtain a reactive additive, while in the second derivative containing 8 phosphate groups, denoted as 8PS, all epoxy groups were converted, thus an additive modifier was obtained. The silsesquioxanes containing phosphorus atoms and the reactive phosphorus-free silsesquioxane derivative (octakis[(3-glycidoxypropyl)dimethylsiloxy]octasilsesquioxane (8GS)) were used to prepare hybrid materials based on epoxy resin. To compare the impact of the structure of silsesquioxane derivatives on the properties of hybrid materials, a number of samples containing 1, 5, and 10% of the modifiers making a series of epoxy materials containing additive or reactive modifiers, were obtained. The modified epoxies were studied using scanning electron microscopy and energy-dispersive X-ray spectroscopy (SEM-EDS), thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), nanoindentation, water contact angle, and cone calorimetry tests to assess the effects of the modifier structure on the physicochemical properties of the investigated materials.

Cardanol derived P, Si and N based precursors to develop flame retardant phenolic foam

A novel eco-friendly halogen-free cardanol-based flame retardant with P, Si, and N on the chain backbone (PSNCFR) was synthesized and incorporated into phenolic foams (PFs). PSNCFR was comprehensively investigated via Fourier transform infrared spectroscopy and nuclear magnetic resonance. PSNCFR endowed PFs with flame retardancy, contributed to generating a composite char defense against flames, and efficiently prevented smoking from PFs. PSNCFR introduction improved the flexural strength of the PFs to approximately 155% of that of pristine PF. PSNCFR-modified PFs displayed a high limiting oxygen index value of 41.9%. The results of cone calorimeter show that the mean heat release rate, mean effective heat of combustion, and total heat release of the PSNCFR-modified PFs reduced by 26.92%, 35.71%, and 31.25%, respectively. In particular, the total smoke production of the PSNCFR-modified PFs decreased by 64.55%, indicating excellent smoke inhibition. As for the mechanism, the condensation and gas phases during pyrolysis were responsible for the synergistic flame retardancy in the modified PFs. The findings demonstrate that PSNCFR can be used in PF preparation to overcome their drawbacks of internal brittleness and flammability.

Highly Effective Flame-Retardant Rigid Polyurethane Foams: Fabrication and Applications in Inhibition of Coal Combustion

The extemporaneous combustion of coal remains a major threat to safety in coal mines because such fire accidents result in casualties and significant property loss, as well as serious environmental pollution. This work proposed the fabrication of flame-retardant rigid polyurethane foam (RPUF) containing expandable graphite as char expander/sealant with melamine phosphosphate and 2-carboxyethyl (phenyl)phosphinic acid as char inducer and radical trapping agents. The as-prepared RPUF successfully inhibited coal combustion by forming thermally stable high graphitic content expandable intumescent char sealing over the coal. The RPUF achieved UL-94 V-0 rating in addition to significant reductions in peak heat release, total heat release, and CO and CO₂ yields. The external and the internal residual char structure was studied by X-ray photoelectron spectra, Raman spectroscopy, and real-time Fourier transform infrared spectra techniques, and a flame-retardant mode of action has been proposed. This work provides important insight into a facile fabrication of highly efficient and economical flame-retardant RPUF to inhibit the spontaneous combustion of coal.

Electrostatic-Interaction-Driven Assembly of Binary Hybrids towards Fire-Safe Epoxy Resin Nanocomposites

Manganese dioxide (MnO₂), as a promising green material, has recently attracted considerable attention of researchers from various fields. In this work, a facile method was introduced to prepare binary hybrids by fabricating three-dimensional (3D) zinc hydroxystannate (ZHS) cubes on two-dimensional (2D) MnO₂ nanosheets towards excellent flame retardancy and toxic effluent elimination of epoxy (EP) resin. Microstructural analysis confirmed that the morphologies and structures of MnO₂@ZHS binary hybrids were well characterized, implying the successful synthesis. Additionally, the morphological characterization indicated that MnO₂@ZHS binary hybrids could achieve satisfactory interfacial interaction with the EP matrix and be well dispersed in nanocomposites. Cone calorimeter test suggested that MnO₂@ZHS binary hybrids effectively suppressed the peak of heat release rate and total heat release of EP nanocomposites, performing better than MnO₂ or ZHS alone. Condensed-phase analysis revealed that MnO₂@ZHS binary hybrids could promote the char density and graphitization degree of char residues and thereby successfully retard the permeation of oxygen and flammable gases. Moreover, through the analysis of gas phase, it can be concluded that MnO₂@ZHS binary hybrids could efficiently suppress the production of toxic gases during the degradation of EP nanocomposites. This work implies that the construction of 2D/3D binary hybrids with an interfacial interaction is an effective way to fabricate high-performance flame retardants for EP.