Thermal decomposition, combustion and flame-retardancy of epoxy resins?a review of the recent literature

Preparation of Low-Viscosity Epoxy Resin Sealing Agent and Evaluation of Injection, Plugging, and Degradation Properties

The technology of water plugging and increasing production in high water cut reservoirs of low permeability is a common problem in the industry. Epoxy resin, displaying excellent mechanical properties and adherent performance, can easily inject a tiny crack, forming a long-term blocking barrier. This study aimed to investigate an easily injectable degradable epoxy resin sealing material. The injectable performance, long-term stability, and mechanical and plugging properties were comparatively analyzed in the fractured core, and the degradable performance was discussed in the degrading solution. The result showed that the range of R (R is the ratio of EOG and MHHPA) from 1 to 1.1 and the mass fraction range of EMI from 0.01 to 4 wt % are the optimal formulations (EOGM). The curing time from 1 to 12 h could be regulated by adjusting the dosage of EMI, as well as the strength being more than 60 MPa. The plugging agent's initial viscosity is lower than 100 MPa s at 20 °C and injecting pressure is lower than 0.1 MPa. After curing for 24 h, compressive strength was more than 72.76 MPa, 3.6 times higher than that of cement, and the adhesion strength was 4.41 MPa when the contact area was 75.93 cm3. Breakthrough pressures for sealing 1-5 mm fractures were all more than 10 MPa, and the breakthrough pressure for 1 mm crack even reached 29.4 MPa. Epoxy resin/acid anhydride system could be degraded in a mixed solution of phenol-potassium salt-heavy aromatics within 7 days at 60-100 °C, which reduced the plugging well risk of the epoxy resin plugging agent. These results suggest that an epoxy resin/acid anhydride plugging agent can be employed effectively and safely for the injection of tiny cracks, which is of great engineering significance.

Quantification of the composition of pyrolysis oils of complex plastic waste by gas chromatography coupled with mass spectrometer detector

Waste valorisation through pyrolysis generates solid, liquid and gaseous fractions that need to be deeply characterised in order to try to recover secondary raw materials or chemicals. Depending on the waste and the process conditions, the liquid fraction obtained (so-called pyrolysis oil) can be very complex. This work proposes a method to quantitatively measure the composition of pyrolysis oils coming from three types of polymeric waste: (1) plastic packaging from sorting plants of municipal solid waste, (2) plastic rich fractions rejected from sorting plants of waste of electrical and electronic equipment and (3) end-of-life carbon/glass fibre reinforced thermoset polymers. The proposed methodology uses a gas chromatography (GC) coupled with mass spectrometer detector (MS) analytical technique, a certified saturated alkanes' mix, an internal standard and fourteen model compounds. Validation of the methodology concluded that the average relative error was between -59 wt% and +62 wt% (with standard deviations between 0 wt% and 13 wt%). Considering that the state-of-the-art scenario to quantify complex plastic pyrolysis oils as a whole is almost none and that they are usually evaluated only qualitatively based on the area percentage of the GC-MS chromatograms, the presented quantification methodology implies a clear step forward towards complex pyrolysis oil compositional quantification in a cost-effective way. Besides, this quantification methodology enables determining what proportion is being detected by GC-MS with respect to the total oil. Finally, the presented work includes all the Kováts RI for complex temperature-program gas chromatography of all the signals identified in the analysed pyrolysis oils, to be readily available to other researchers towards the identification of chemical compounds in their studies.

Effects of Additives on the Mechanical and Fire Resistance Properties of Pultruded Composites

Under high temperatures, fiber-reinforced polymers are destroyed, releasing heat, smoke, and harmful volatile substances. Therefore, composite structural elements must have sufficient fire resistance to meet the requirements established by building codes and regulations. Fire resistance of composite materials can be improved by using mineral fillers as flame-retardant additives in resin compositions. This article analyzes the effect of fire-retardant additives on mechanical properties and fire behavior of pultruded composite profiles. Five resin mixtures based on vinyl ester epoxy and on brominated vinyl ester epoxy modified with alumina trihydrate and triphenyl phosphate were prepared for pultrusion of strip profiles of 150 mm × 3.5 mm. A series of tests have been conducted to determine mechanical properties (tensile, flexural, compression, and interlaminar shear) and fire behavior (ignitability, flammability, combustibility, toxicity, smoke generation, and flame spread) of composites. It was found that additives impair mechanical properties of materials, as they the take place of reinforcing fibers and reduce the volume fraction of reinforcing fibers. Profiles based on non-brominated vinyl ester epoxy have higher tensile, compressive, and flexural properties than those based on brominated vinyl ester epoxy by 7%, 30%, and 36%, respectively. Profiles based on non-brominated epoxy resin emit less smoke compared to those based on brominated epoxy resin. Brominated epoxy-based profiles have a flue gas temperature which is seven times lower compared to those based on the non-brominated epoxy. Mineral fillers retard the spread of flame over the composite material surface by as much as 4 times and reduce smoke generation by 30%.

Study on the Flame Retardancy of Rigid Polyurethane Foam with Phytic Acid-Functionalized Graphene Oxide

A rigid polyurethane foam (RPUF) composite was prepared by compounding phytic acid (PA)-functionalized Graphite oxide (PA-GO) with flame-retardant poly (Ammonium phosphate) (APP) and expandable graphite (EG). The effects of PA-GO on the thermal, flame-retardant, and mechanical properties of RPUF were studied using a thermogravimetric analyzer, a limiting oxygen index (LOI) tester, a UL-94 vertical combustion tester, a cone calorimeter, scanning electron microscopy, and a universal tensile testing machine. The results indicated that there was a significant synergistic flame-retardant effect between PA-GO and the intumescent flame retardants (IFR) in the RPUF matrix. Compared with RPUF-1, the addition of 0.3 wt% PA-GO could increase LOI from 25.7% to 26.5%, increase UL-94 rating from V-2 to V-0, and reduce the peak heat release rate (PHRR) and total heat release rate (THR) by 28.5% and 22.2%, respectively. Moreover, the amount of residual char increased from 22.2 wt% to 24.6 wt%, and the char layer was continuous and dense, with almost no holes. Meanwhile, the loss of mechanical properties was apparently lightened.

Biobased Epoxy Composites Reinforced with Acetylated Corn Straw

Corn straw/epoxy resin composites (CS/ECs) and maleic anhydride acetylated CS/ECs (MA-CS/ECs) were prepared through dry mixing and high-temperature curing. Corn straw is a kind of abundant, eco-friendly, and low-cost biomass material. Unmodified and modified corn straws were characterized using Fourier transform infrared spectroscopy, scanning electron microscopy (SEM), and X-ray photoelectron spectroscopy (XPS). The interfacial affinity of the composite was testified by the contact angle. The results of XPS and SEM demonstrated that maleic anhydride had been successfully bonded onto the structure of corn straw. Corn straw particle-reinforced epoxy resin composites were prepared using a casting and molding process. Results showed that the MA-CS/EC had better impact and flexural resistance than the unmodified corn straw/epoxy resin composites when the corn straw addition was 15 wt %. The result of the contact angle showed that the interfacial compatibility between composites is also stronger than that of CS/EC.

Effect of Flame Treatment on Bonding Performance of GF/EP Pultrusion Sheets Used for VARI Process

This paper presents an easy and low-cost flame treatment method to improve the bonding performance of GF/EP (Glass Fiber-Reinforced Epoxy) pultrusion plates, which are using widely for large size wind blades. In order to explore the effect of flame treatment on the bonding performance of the precast GF/EP pultruded sheet vs. the infusion plate, the GF/EP pultruded sheets were treated with different flame treatment cycles and were embedded in the fiber fabrics during the vacuum-assisted resin infusion process (VARI). The bonding shear strengths were measured by tensile shear tests. It is found that after 1, 3, 5, and 7 flame treatments, the tensile shear strength between the GF/EP pultrusion plate and infusion plate increased by 8.0%, 13.3%, 22.44%, and -2.1%, respectively. This indicates that the maximum tensile shear strength can be obtained after five times of flame treatment. In addition, DCB and ENF tests were also adopted to characterize the fracture toughness of the bonding interface with the optimal flame treatment. It is found that the optimal treatment gives increments of 21.84% and 78.36% for G I C and G II C, respectively. Finally, the surficial topography of the flame-treated GF/EP pultruded sheets were characterized by optical microscopy, SEM, contact angle test, FTIR, and XPS. The results show that flame treatment plays an impact on the interfacial performance through the combination of physical meshing locking and chemical bonding mechanism. Proper flame treatment would remove the weak boundary layer and mold release agent on the surface of the GF/EP pultruded sheet, etch the bonding surface and improve the oxygen-containing polar groups, such as C-O and O-C=O, to improve the surface roughness and surface tension coefficient of pultruded sheet to enhance the bonding performance. Excessive flame treatment destroys the integrity of epoxy matrix on bonding surface which results into the exposure of the glass fiber, and the carbonization of release agent and resin on the surface loosen the surficial structure, which reduces the bonding properties.

Mixed bromine/chlorine transformation products of tetrabromobisphenol A formed in the combustion of printed circuit boards: Emission characteristics and transformation pathways

Recently, mixed bromine/chlorine transformation products of tetrabromobisphenol A (Cl_yBr_xBPAs) were found to be possibly related to the thermal treatment processes of electronic wastes. To explore their emission characteristics and formation mechanism, printed circuit board scraps were combusted in a tube furnace, under the temperature from 25 °C to 600 °C. The emission factor of the debromination products of tetrabromobisphenol A (Br_xBPAs) was the highest, whereas that of Cl_yBr_xBPAs was the lowest. Among three phases, most of the target compounds were partitioned into the oil and particle phases, and only negligible gaseous 2-BrBPA and bisphenol A were detected. The emission rates of most compounds were fastest at 300 °C, although 2-BrBPA, 2,6-Br₂BPA, and 2-Cl-6-BrBPA peaked at 350 °C. Among the chemicals in total emission, 2-BrBPA was the dominant congener in Br_xBPAs, whereas 2-Cl-2',6,6'-Br₃BPA, 2-Cl-2',6^#-Br₂BPA, and Σ₂Cl₁Br₁BPAs shared similar proportions in Cl_yBr_xBPAs. Meanwhile, the composition profiles at 300 °C showed that 2,2',6-Br₃BPA and 2-Cl-2',6,6'-Br₃BPA occupied the largest proportions in Br_xBPAs and Cl_yBr_xBPAs, respectively. To reveal the possible transformation pathways, the Gibbs free energy was calculated based on a radical substitution reaction. After "•Br" removal from tetrabromobisphenol A or other Br_xBPAs, the intermediate was more easily combined with "•H" than with "•Cl." In addition, the Cl_yBr_xBPA formation via "-•H + •Cl" by Br_xBPAs is nonspontaneous, thus limiting the further generation of Cl_yBr_xBPAs. This study not only provides ideas for the study of other mixed halogenated products, but also provides constructive suggestions for environmental source analysis by combining previous research on the occurrence of Cl_yBr_xBPAs in various environmental matrices.

Modified oligoether-diamine synthesis for the preparation of crystallizable polymers based on epoxyurethane oligomers

A modified synthetic method for amino-terminated oligo tetramethylene oxides is presented. Diamines were synthesized via a three-step route from oligo tetramethylene oxide diol with an average molecular weight of 2000. The final step – oligoether-diphthalimide hydrazinolysis – has been improved. The yield of the target product has been shown to be more than 1.5 times higher when the molar ratio of the reacting components was changed. The oligoether-diamine and the reaction intermediates have been identified by 1H and 13C NMR spectroscopy. It has been demonstrated that the synthesized amine can be used as a curing agent for epoxy urethane oligomers. It is shown that the glass transition temperature of the cured elastomers is lower than −70 °C. These elastomers can be recommended for the use in the conditions of the Arctic and the Far North or Far South of the globe.

The Effect of Polyepoxyphenylsilsesquioxane and Diethyl Bis(2-hydroxyethyl)aminomethylphosphonate on the Thermal Stability of Epoxy Resin

Polyepoxyphenylsilsesquioxane (PEPSQ) and diethyl bis(2-hydroxyethyl) aminomethylphosphonate (DBAMP) can improve the flame retardancy of epoxy resin (EP). In this paper, the results of the limiting oxygen index (LOI) and UL94 tests exhibited that PEPSQ and DBAMP had good synergistic flame retardancy. The non-isothermal degradation kinetics of EP containing PEPSQ and DBAMP was investigated by the Kissinger and Flynn-Wall-Ozawa methods. The results of the Kissinger method displayed that the addition of two flame retardants, PEPSQ and DBAMP, can slightly enhance the activation energy of EP, indicating that the additives delayed the thermal degradation of EP. The Flynn-Wall-Ozawa method further confirmed that the activation energy of EP during the whole thermal degradation process can be significantly increased by addition of the two flame retardants PEPSQ and DBAMP. When the degree of conversion exceeded 80%, the increase was more significant. This illustrated that the flame retardants finally achieved the purpose of improving the flame retardancy of EP by stabilizing the char layer.

Advances on Thermally Conductive Epoxy-Based Composites as Electronic Packaging Underfill Materials-A Review

The integrated circuits industry has been continuously producing microelectronic components with ever higher integration level, packaging density, and power density, which demand more stringent requirements for heat dissipation. Electronic packaging materials are used to pack these microelectronic components together, help to dissipate heat, redistribute stresses, and protect the whole system from the environment. They serve an important role in ensuring the performance and reliability of the electronic devices. Among various packaging materials, epoxy-based underfills are often employed in flip-chip packaging. However, widely used capillary underfill materials suffer from their low thermal conductivity, unable to meet the growing heat dissipation required of next-generation IC chips with much higher power density. Many strategies have been proposed to improve the thermal conductivity of epoxy, but its application as underfill materials with complex performance requirements is still difficult. In fact, optimizing the combined thermal-electrical-mechanical-processing properties of underfill materials for flip-chip packaging remains a great challenge. Herein, state-of-the-art advances that have been made to satisfy the key requirements of capillary underfill materials are reviewed. Based on these studies, the perspectives for designing high-performance underfill materials with novel microstructures in electronic packaging for high-power density electronic devices are provided.

Polyols and Polyurethane Foams Obtained from Mixture of Metasilicic Acid and Cellulose

Hydroxyalkylation of the mixture of metasilicic acid and cellulose with glycidol and ethylene carbonate leads to a polyol suitable to obtain rigid polyurethane foams. The composition, structure, and physical properties of the polyol were studied in detail. The obtained foams have apparent density, water absorption, and polymerization shrinkage, as well as heat conduction coefficients similar to conventional, rigid polyurethane foams. The polyols and foams obtained from environmentally unobtrusive substrates are easily biodegradable. Additionally, the obtained foams have high thermal resistance and are self-extinguishing. Thermal exposure of the foams leads to an increase of the compressive strength of the material and further reduces their flammability, which renders them suitable for use as heat insulating materials.

Effect of Thermal Exposure on Residual Properties of Wet Layup Carbon Fiber Reinforced Epoxy Composites

Ambient cured wet layup carbon fiber reinforced epoxy composites used extensively in the rehabilitation of infrastructure and in structural components can be exposed to elevated temperature regimes for extended periods of time of hours to a few days due to thermal excursions. These may be severe enough to cause a significant temperature rise without deep charring as through fires at a small distance and even high-temperature industrial processes. In such cases, it is critical to have information related to the post-event residual mechanical properties and damage states. In this paper, composites are subjected to a range of elevated temperatures up to 260 °C over periods of time up to 72 h. Exposure to elevated temperature regimes is noted to result in a competition between the mechanisms of post-cure that can increase the levels of mechanical characteristics, and the deterioration of the resin and the bond between the fibers and resin that can reduce them. Mechanical tests indicate that tensile and short beam shear properties are not affected negatively until the highest temperatures of exposure considered in this investigation. In contrast, all elevated temperature conditions cause deterioration in resin-dominated characteristics such as shear and flexure, emphasizing the weakness of this mode in layered composites formed from unidirectional fabric architectures due to resin deterioration. Transitions in failure modes are correlated through microscopy to damage progression both at the level of fiber-matrix interface integrity and through the bulk resin, especially at the inter-layer level. The changes in glass transition temperature determined through differential scanning calorimetry can be related to thresholds that indicate changes in the mechanisms of damage.

Environmental, Health, and Legislation Considerations for Rational Design of Nonreactive Flame-Retardant Additives for Polymeric Materials: Future Perspectives

Increasing polymer usage has demanded functional additives that decrease fire hazards for end users. While traditional flame-retardant (FR) additives, such as halogenated, phosphorus, and metal hydroxides, greatly reduce flammability and associated fire hazards, research has continually exposed a litany of health and environmental safety concerns. This perspective aims to identify the key components of a successful FR additive and address material, environmental, and health concerns of existing additives. Legislation surrounding FRs and persistent organic pollutants is also discussed to highlight political perception that has resulted in the increased chemical regulations and subsequent banning of FR additives. Finally, future directions of this field regarding nonreactive additives, focusing on the use of bioinspired materials and transition metal chemistries to produce alternatives for polymers with efficacies surpassing traditional additives are presented.

Airborne emissions from combustion of graphene nanoplatelet/epoxy composites and their cytotoxicity on lung cells via air-liquid interface cell exposure in vitro

Graphene nanoplatelet (GNP) as a nanofiller improves the mechanical strength, electrical conductivity, and flame retardancy of the polymers significantly. With an increasing number of GNP-reinforced products, a careful safety assessment is needed to avoid social and economic setbacks. However, no study has addressed the effects of combustion-generated emissions from GNP-reinforced products in the lung, the most sensitive exposure route to airborne particles. Therefore, we studied the influence of GNP as a nanofiller on the emitted particles and polycyclic aromatic hydrocarbons (PAHs), and cytotoxicity of the emissions from the combustion of pure epoxy (EP) and GNP-reinforced epoxy (EP-GNP). GNP was not detected in the airborne emissions. PAHs were found in airborne particles of both emissions from EP and EP-GNP, with some differences in their concentrations. A first hazard assessment was performed on human alveolar epithelial cells exposed to the airborne emissions at air-liquid interface conditions. At 24 h and 96 h after the exposure, similar responses were observed between EP and EP-GNP except an acute transient decrease in mitochondrial activity after exposure to the emissions from EP-GNP. Both emissions from EP and EP-GNP had no acute effects on membrane integrity, cell morphology or expression of anti-oxidative stress markers (HMOX1 and SOD2 genes). Meanwhile, both emissions induced the activation of the aryl hydrocarbon receptor (CYP1A1 gene) and a transient (pro-) inflammatory response (MCP-1), but the effects between EP and EP-GNP were not significantly different.

Study on Fire Behavior, Thermal Stability and Degradation Kinetics of Thiol-Ene with Poly(aminopropyl/phenyl)silsesquioxane

In this article, the flame retardant poly(aminopropyl/phenyl)silsesquioxane (PA) was incorporated into thiol-ene (TE), to obtain a flame-retardant thiol-ene (FRTE) composite. The cone calorimeter (CONE) measurement results showed that, compared with neat TE, the peak of heat release rate (PHRR) and total heat release (THR) of FRTE have decreased by almost 23.7% and 14.5%, respectively. Thermogravimetric analysis (TGA) results further confirmed that the flame retardant PA could induce the initial thermal degradation of TE, and increased the amounts of residual char. Moreover, the activation energies of FRTE were calculated through the Kissinger and Flynn–Wall–Ozawa methods. Compared with the neat TE, the activation energies of FRTE were raised by the addition of PA. It indicated that the flame retardant PA promoted cross-linking reactions of TE, to form a compact char layer and retarded further the thermal degradation of the polymer matrix.

Preparation, Structure and Properties of Urethane-Containing Elastomers Based on Epoxy Terminal Oligomers

The effect of polyester oligoethylene adipate molecular weight, diisocyanate structure, and chain extender on the properties of epoxyurethane-based oligomer elastomers was studied in this research. Oligoethylene adipates were obtained via polycondensation of adipic acid and ethylene glycol. Epoxyurethane oligomers were synthesized according to a two-step route with an oligodiisocyanate as an intermediate product. The elastomers with hard urethane hydroxyl blocks were synthesized from oligodiisocyanates. The deformation and strength properties of the elastomers were studied.

Comparative Study of Different Methods of Synthesis and Their Effect on the Thermomechanical Properties of a Halogenated Epoxy-Based Flame-Retardant Resin

The work presented in this paper deals with the comparative synthesis of diglycidyl ether-based tetrabromobisphenol-A(TBBPA) using both conventional and nonconventional methods in order to explore materials for better industrial applications with respect to effective yield, cost, and time consideration. The conventional method involved the polycondensation of TBBPA and epichlorohydrin in the presence of an alkali catalyst. The nonconventional routes adopted for the synthesis of the material involved ultrasonication, microwave irradiation, and UV light exposure. The Fourier transform infrared spectroscopy spectra of all the synthesized materials of the resin were found to be identical, and the X-ray diffraction analysis showed the material as amorphous. The mechanical studies of the resins revealed that all these resins synthesized by different methods are strong and possess high viscosity. Based on the overall thermal, rheological, and excellent hydrophobic properties, it can serve as an excellent flame retardant.

Influence of crosslinking density on the mechanical and thermal properties of plant oil-based epoxy resin

Plant oil-based epoxy resins are of great interest due to their ecological and economic necessity. Previous studies suggested that the crosslinking density had a considerable influence on the mechanical and thermal properties of plant oil-based epoxy resins. However, so far, the relationship between the crosslinking density and the thermo-mechanical properties of plant oil-based epoxy resins is not clear. To address this issue, model tung oil-based epoxy resins with different crosslinking densities were fabricated to investigate the influence of crosslinking density on the mechanical and thermal properties of tung oil-based epoxy resins. Results show that the tensile strength, Young's modulus, and glass transition temperature are linearly increased with increasing crosslinking density. The elongation at break and tensile toughness show nonlinear downward trends as the crosslinking density increases. The elongation at break decreases gently at first, then dramatically, and finally slowly as the crosslinking density increases. The tensile toughness declines sharply at first and then slowly with increasing crosslinking density. The relationship between the thermostability and the crosslinking density is complex, because the thermostability is determined by both the molecular structure of the curing system and the crosslinking density. These results provide some information for designing plant oil-based epoxy resins according to the requirements of their applications.

Plant oil-based epoxy resins are of great interest due to their ecological and economic necessity. In this study, the relationship between the crosslinking density and the thermo-mechanical properties of tung oil-based epoxy resins was established.

One-Step Reduction of Graphene Oxide with Phosphorus/Silicon-Containing Compound and Its Flame Retardancy in Epoxy Resin

A novel graphene-based phosphorus/silicon-containing flame retardant (GO-DOPO-V) was obtained via one-step reduction of graphene oxide (GO) with phosphorus/silicon-containing compound (DOPO-V). The Fourier transform infrared (FTIR) spectroscopy, X-ray photoelectron spectrometer (XPS), Atomic force microscope (AFM) and Thermogravimetric analysis (TGA) measurements were used to confirm the structure and morphology. After incorporation of 2 wt% GO-DOPO-V, the maximum decreases of 28.8% in peak heat release rate and 15.6% in total heat release are achieved compared to that of pure epoxy resin (EP). Furthermore, TGA and Scanning electron microscopy (SEM) measurement showed that GO-DOPO-V significantly enhanced the thermal stability and residual char strength of EP. Thus, attributed to the barrier effect of GO and phosphorus/silicon layer formation by DOPO-V, GO-DOPO-V was a high-efficient flame retardant to improve the combustion behavior of EP nanocomposite.

A Study of Thermal Degradation and Fire Behaviour of Polymer Composites and Their Gaseous Emission Assessment

The use of polymer composite materials in the aeronautics and automotive sectors has increased dramatically, and their fire behaviour has become a critical parameter in terms of fire safety. On this premise, it is critical to demonstrate that these composite materials constitute elements whose safety justifies a high level of confidence. This is based on their combustibility and the rate at which flammable and toxic gaseous species are emitted. Thus, strict fire safety regulations are enforced by the relevant authorities concerned because of their potential fire risk. This study analysed papers published between 1970 and 2021 that described the devices used to characterise the thermal behaviour of composite materials at various scales. The objective was to highlight the thermophysical phenomena, making it possible to accurately assess the flammability and thermal stability of polymer composite materials. The results of this research reveal that the small-scale facilities provide detailed understanding and mastery of the thermal reaction properties of the composites. While with the medium scale, the extended fire reaction parameters, which are the key indicators of the fire safety performance, can be determined. On a large scale, the tests were carried out using devices such as the NexGen burner recommended by the FAA. Therefore, with such assays, it is possible to assess the rates of thermal degradation as well as quantified pyrolysis gases. However, compared to other scales, there were very few works on a large scale. In addition, by focusing on the polluting nature of synthetic composite materials, there is also few research studies aimed at designing new polymer composite materials from biological sources.

Biobased Polyurethane Composite Foams Reinforced with Plum Stones and Silanized Plum Stones

In the following study, ground plum stones and silanized ground plum stones were used as natural fillers for novel polyurethane (PUR) composite foams. The impact of 1, 2, and 5 wt.% of fillers on the cellular structure, foaming parameters, and mechanical, thermomechanical, and thermal properties of produced foams were assessed. The results showed that the silanization process leads to acquiring fillers with a smoother surface compared to unmodified filler. The results also showed that the morphology of the obtained materials is affected by the type and content of filler. Moreover, the modified PUR foams showed improved properties. For example, compared with the reference foam (PUR_REF), the foam with the addition of 1 wt.% of unmodified plum filler showed better mechanical properties, such as higher compressive strength (~8% improvement) and better flexural strength (~6% improvement). The addition of silanized plum filler improved the thermal stability and hydrophobic character of PUR foams. This work shows the relationship between the mechanical, thermal, and application properties of the obtained PUR composites depending on the modification of the filler used during synthesis.

Melt Processable Novolac Cyanate Ester/Biphenyl Epoxy Copolymer Series with Ultrahigh Glass-Transition Temperature

The rapid progress in silicon carbide (SiC)-based technology for high-power applications expects an increasing operation temperature (up to 250 °C) and awaits reliable packaging materials to unleash their full power. Epoxy-based encapsulant materials failed to provide satisfactory protection under such high temperatures due to the intrinsic weakness of epoxy resins, despite their unmatched good adhesion and processability. Herein, we report a series of copolymers made by melt blending novolac cyanate ester and tetramethylbiphenyl epoxy (NCE/EP) that have demonstrated much superior high-temperature stability over current epoxies. Benefited from the aromatic, rigid backbone and the highly functional nature of the monomers, the highest values achieved for the copolymers are as follows: glass-transition temperature (T_g) above 300 °C, decomposition onset above 400 °C, and char yield above 45% at 800 °C, which are among the highest of the known epoxy chemistry by far. Moreover, the high-temperature aging (250 °C) experiments showed much reduced mass loss of these copolymers compared to the traditional high-temperature epoxy and even the pure NCE in the long term by suppressing hydrolysis degradation mechanisms. The copolymer composition, i.e., NCE to EP ratio, has found to have profound impacts on the resin flowability, thermomechanical properties, moisture absorption, and dielectric properties, which are discussed in this paper with in-depth analysis on their structure-property relationships. The outstanding high-temperature stability, preferred and adjustable processability, and the dielectric properties of the reported NCE/EP copolymers will greatly stimulate further research to formulating robust epoxy molding compounds (EMCs) or underfill for packaging next-generation high-power electronics.

Fire-Safe Polymer Composites: Flame-Retardant Effect of Nanofillers

Currently, polymers are competing with metals and ceramics to realize various material characteristics, including mechanical and electrical properties. However, most polymers consist of organic matter, making them vulnerable to flames and high-temperature conditions. In addition, the combustion of polymers consisting of different types of organic matter results in various gaseous hazards. Therefore, to minimize the fire damage, there has been a significant demand for developing polymers that are fire resistant or flame retardant. From this viewpoint, it is crucial to design and synthesize thermally stable polymers that are less likely to decompose into combustible gaseous species under high-temperature conditions. Flame retardants can also be introduced to further reinforce the fire performance of polymers. In this review, the combustion process of organic matter, types of flame retardants, and common flammability testing methods are reviewed. Furthermore, the latest research trends in the use of versatile nanofillers to enhance the fire performance of polymeric materials are discussed with an emphasis on their underlying action, advantages, and disadvantages.

Material recovery from electronic waste using pyrolysis: Emissions measurements and risk assessment

Electronic waste (e-waste) generation has been growing in volume worldwide, and the diversity of its material composition is increasing. Sustainable management of this material is critical to achieving a circular-economy and minimizing environmental and public health risks. This study's objective was to investigate the use of pyrolysis as a possible technique to recover valuable materials and energy from different components of e-waste as an alternative approach for limiting their disposal to landfills. The study includes investigating the potential environmental impact of thermal processing of e-waste. The mass loss and change in e-waste chemicals during pyrolysis were also considered. The energy recovery from pyrolysis was made in a horizontal tube furnace under anoxic and isothermal conditions of selected temperatures of 300 °C, 400 °C, and 500 °C. Critical metals that include the rare earth elements and other metals (such as In, Co, Li) and valuable metals (Au, Ag, Pt group) were recovered from electronic components. Pyrolysis produced liquid and gas mixtures of organic compounds that can be used as fuels. Still, the process also emitted particulate matter and semi-volatile organic products, and the remaining ash contained leachable pollutants. Furthermore, toxicity characteristics leaching procedure (TCLP) of e-waste and partly oxidized products were conducted to measure the levels of pollutants leached before and after pyrolysis at selected temperatures. TCLP result revealed the presence of heavy metals like As, Cr, Cd, and Pd. Lead was found at 160 mg/L in PCBs leachate, which exceeded the toxicity characteristics (TC) limit of 5 mg/L. Liquid sample analysis from TCLP also showed the presence of C₁₀-C₁₉ components, including benzene. This study's results contribute to the development of practical recycling alternative approaches that could help reduce health risks and environmental problems and recover materials from e-waste. These results will also help assess the hazard risks that workers are exposed to semi-formal recycling centers.

Multifunctional Ceramic Composite System for Simultaneous Thermal Protection and Electromagnetic Interference Shielding for Carbon Fiber-Reinforced Polymer Composites

Achieving a high electrical conductivity while maintaining a good thermal insulation is often contradictory in the material design for the goal of simultaneous thermal protection and electromagnetic interference shielding. The reason is that materials with a high electrical conductivity often pertain a high thermal conductivity. To address this challenge, this study reports a multifunctional ceramic composite system for carbon fiber-reinforced polymer composites. The fabricated multifunctional ceramic composite system has a multilayer structure. The polymer-derived SiCN ceramic reinforced with yttria-stabilized zirconia fibers serves as the thermal protection and impedance-matching layer, while the yttria-stabilized zirconia fiber-reinforced SiCN ceramic with carbon nanotubes provides the electromagnetic interference shielding. The thermal conductance of the multilayered ceramic composite is about 22.5% lower compared to that of the carbon fiber-reinforced polymer composites. The thermal insulation test during the steady-state condition shows that the hybrid composite can be used up to 300 °C while keeping the temperature reaching the surface of carbon fiber-reinforced polymer composites at around 167.8 °C. The flame test was used to characterize the thermal protection capability under transient conditions. The hybrid composite showed temperature differences of 72.9 and 280.7 °C during the low- and high-temperature settings, respectively. The average total shielding efficiency per thickness of the fabricated four-layered ceramic composite system was 21.45 dB/mm, which showed a high reflection-dominant electromagnetic interference shielding. The average total shielding efficiency per thickness of the eight-layered composite system was 16.57 dB/mm, revealing a high absorption-dominant electromagnetic interference shielding. Typical carbon fiber-reinforced polymer composites reveal a reflection-dominant electromagnetic interference shielding. The electrons can freely move in the percolated carbon nanotubes within the inner layers of the composite material, which provide the improved electromagnetic interference shielding ability. The movement of electrons was impeded by the top and bottom layers whose thermal conduction relies on the lattice vibrations, resulting in a satisfactory thermal insulation of the composite materials and impedance matching with the free space. Results of this study showed that materials with a good thermal insulation and electromagnetic interference shielding can be obtained simultaneously by confining the electron movement inside the materials and refraining their movement at the skin surface.