Manufacturing, thermal stability, and flammability properties of polypropylene containing new single molecule intumescent flame retardant

Sisal-Fiber-Reinforced Polypropylene Flame-Retardant Composites: Preparation and Properties

Natural-fiber-reinforced polypropylene (PP) composites with a series of advantages including light weight, chemical durability, renewable resources, low in cost, etc., are being widely used in many fields such as the automotive industry, packaging, and construction. However, the flammability of plant fiber and the PP matrix restricts the application range, security, and use of these composites. Therefore, it is of great significance to study the flame retardants of such composites. In this paper, sisal-fiber-reinforced polypropylene (PP/SF) flame-retardant composites were prepared using the two-step melt blending method. The flame retardant used was an intumescent flame retardant (IFR) composed of silane-coated ammonium polyphosphate (Si-APP) and pentaerythritol (PER). The influence of different blending processes on the flammability and mechanical properties of the composites was analyzed. The findings suggested that PP/SF flame-retardant composites prepared via different blending processes showed different flame-retardant properties. The (PP/SF)/IFR composite prepared by PP/SF secondary blending with IFR showed excellent flame-retardant performance, with a limited oxygen index of about 28.3% and passing the UL-94 V-0 rating (3.2 mm) in the vertical combustion test. Compared with the (PP/IFR) /SF composite prepared by a matrix primarily blended with IFR and then secondly blended with SF, the peak heat release rate (pk HRR) and total heat release (THR) of the (PP/SF)/IFR composite decreased by 11.3% and 13.7%, respectively. In contrast, the tensile strength of the (PP/SF)/IFR system was 5.3% lower than that of the (PP/IFR)/SF system; however, the overall mechanical (tensile, flexural, and notched impact) properties of the composites prepared using three different mixing processes were similar.

Synergistic Effect of 4A Molecular Sieve on Intumescent Ternary H-Bonded Complex in Flame-Retarding of Polypropylene

In this study, a ternary hydrogen (H)-bonded complex intumescent flame retardant (TH-IFR) of melamine (ME) · phosphoric acid (PA)…pentaerythritol (PER) was synthesized through hydrothermal reaction. The combination of the synthesized TH-IFR with 4A molecular sieve as the synergist was used for the first time to improve the flame retardancy of polypropylene (PP). The involved structure, morphology, flame retardancy, flame-retarding mechanism and mechanical properties of the prepared PP composites were systematically investigated. The results show that incorporation of 1 wt% synergist 4A shows the optimum synergistic effect, and the flame retardancy and mechanical properties of the flame-retarded (FR) PP composites are significantly improved. Incorporation of 4A could change the pyrolysis process of the entire system and promote the char-forming chemical interaction, thereby further enhancing the flame retardancy of FR PP composite. The synergistically flame-retarding mechanism of 4A is explained by the significantly improved quality and quantity of the solid-phase char layer, which is formed through generation of SiO₂ and Al₂O₃ substances, and also participation of PP macromolecular chains in the final char layer formation during burning. Furthermore, the improved dispersion and compatibility of TH-IFR in the composite is largely beneficial to the improvement of flame retardancy and mechanical properties.

Highly efficient replacement of traditional intumescent flame retardants in polypropylene by manganese ions doped melamine phytate nanosheets

The intumescent flame retardant (IFR) with ammonium polyphosphate (APP) as the main component has many defects in practical applications, more than that, APP can be traced to non-renewable phosphate rock resources. For the foregoing reasons, the melamine phytate supramolecular nanosheet flame retardant incorporating manganese ion (PAMA-Mn) was successfully prepared with a facile and environmental friendly hydrothermal procedure based on renewable bio-based material phytic acid (PA). The flame retardant polypropylene composite (PPI) with 13.5 wt% APP and 4.5 wt% pentaerythritol (PER) failed to the UL-94 test, and its limiting oxygen index (LOI) value was only 26.5%. After 33 wt% of APP was replaced by PAMA-Mn, the PPMn33 incorporating only 18 wt% flame retardant additives passed the UL-94 V-0 rating, and its LOI value was increased to 31.9%. Compared with PP, pHRR and pSPR values of PPMn33 were reduced by 56% and 23%, respectively. The fire retardant mechanism of PPMn33 was thoroughly discussed via a variety of characterization methods. It was found that the peak of the Gram-Schmidt curve of PPMn33 was drastically reduced by 49% relative to that of PPI, indicating a remarkably decrease of combustible volatile products owing to the incorporation of PAMA-Mn, thereby rapidly reducing the fire hazard risk.

Flame Retardant Polypropylenes: A Review

Polypropylene (PP) is a commodity plastic known for high rigidity and crystallinity, which is suitable for a wide range of applications. However, high flammability of PP has always been noticed by users as a constraint; therefore, a variety of additives has been examined to make PP flame-retardant. In this work, research papers on the flame retardancy of PP have been comprehensively reviewed, classified in terms of flame retardancy, and evaluated based on the universal dimensionless criterion of Flame Retardancy Index (FRI). The classification of additives of well-known families, i.e., phosphorus-based, nitrogen-based, mineral, carbon-based, bio-based, and hybrid flame retardants composed of two or more additives, was reflected in FRI mirror calculated from cone calorimetry data, whatever heat flux and sample thickness in a given series of samples. PP composites were categorized in terms of flame retardancy performance as Poor, Good, or Excellent cases. It also attempted to correlate other criteria like UL-94 and limiting oxygen index (LOI) with FRI values, giving a broad view of flame retardancy performance of PP composites. The collected data and the conclusions presented in this survey should help researchers working in the field to select the best additives among possibilities for making the PP sufficiently flame-retardant for advanced applications.

Highly Efficient Composite Flame Retardants for Improving the Flame Retardancy, Thermal Stability, Smoke Suppression, and Mechanical Properties of EVA

Ethylene vinyl acetate (EVA) copolymer has been used extensively in many fields. However, EVA is flammable and releases CO gas during burning. In this work, a composite flame retardant with ammonium polyphosphate (APP), a charring–foaming agent (CFA), and a layered double hydroxide (LDH) containing rare-earth elements (REEs) was obtained and used to improve the flame retardancy, thermal stability, and smoke suppression for an EVA matrix. The thermal analysis showed that the maximum thermal degradation temperature of all composites increased by more than 37 °C compared with that of pure EVA. S-LaMgAl/APP/CFA/EVA, S-CeMgAl/APP/CFA/EVA, and S-NdMgAl/APP/CFA/EVA could achieve self-extinguishing behavior according to the UL-94 tests (V-0 rating). The peak heat release rate (pk-HRR) indicated that all LDHs containing REEs obviously reduced the fire strength in comparison with S-MgAl. In particular, pk-HRR of S-LaMgAl/APP/CFA/EVA, S-CeMgAl/APP/CFA/EVA and S-NdMgAl/APP/CFA/EVA were all decreased by more than 82% in comparison with pure EVA. Furthermore, the total heat release (THR), smoke production rate (SPR), and production rate of CO (COP) also decreased significantly. The average mass loss rate (AMLR) confirmed that the flame retardant exerted an effect in the condensed phase of the composites. Meanwhile, the combination of APP, CFA, and LDH containing REEs allowed the EVA matrix to maintain good mechanical properties.