Poly(lactic acid) nanocomposites with improved flame retardancy and impact strength by combining of phosphinates and organoclay

Recent Advances and Outlook in 2D Nanomaterial-Based Flame-Retardant PLA Materials

Poly (lactic acid) or polylactide (PLA) has gained widespread use in many industries and has become a commodity polymer. Its potential as a perfect replacement for petrochemically made plastics has been constrained by its extreme flammability and propensity to flow in a fire. Traditional flame-retardants (FRs), such as organo-halogen chemicals, can be added to PLA without significantly affecting the material's mechanical properties. However, the restricted usage of these substances causes them to bioaccumulate and endanger plants and animals. Research on PLA flame-retardants has mostly concentrated on organic and inorganic substances for the past few years. Meanwhile, there has been a significant increase in renewed interest in creating environmentally acceptable flame-retardants for PLA to maintain the integrity of the polymer, which is the current trend. This article reviews recent advancements in novel FRs for PLA. The emphasis is on two-dimensional (2D) nanosystems and the composites made from them that have been used to develop PLA nanocomposite (NCP) systems that are flame retarding. The association between FR loadings and efficiency for different FR-PLA systems is also briefly discussed in the paper, as well as their influence on processing and other material attributes. It is unmistakably established from the literature that adding 2D nanoparticles to PLA matrix systems reduces their flammability by forming an intumescent char/carbonized surface layer. This creates a barrier effect that successfully blocks the filtration of volatiles and oxygen, heat and mass transfer, and the release of combustible gases produced during combustion.

Synergistic Enhancement of Flame Retardancy Behavior of Glass-Fiber Reinforced Polylactide Composites through Using Phosphorus-Based Flame Retardants and Chain Modifiers

Flame retardancy properties of neat PLA can be improved with different phosphorus-based flame retardants (FRs), however, developing flame retardant PLA-based engineering composites with maintained mechanical performance is still a challenge. This study proposes symbiosis approaches to enhance the flame retardancy behavior of polylactide (PLA) composites with 20 wt% short glass fibers (GF). This was first implemented by exploring the effects of various phosphorus-based FRs up to 5 wt% in neat PLA samples. Among the used phosphorus-based FRs, the use of only 3 wt% of diphosphoric acid-based FR (P/N), melamine coated ammonium polyphosphate (APPcoated), and APP with melamine synergist (APP/Mel) resulted in achieving the V0 value in a vertical burning test in the neat PLA samples. In addition to their superior efficiency in improving the flame retardancy of neat PLA, P/N had the least negative effect on the final mechanical performance of PLA samples. When incorporated in PLA composites with 20 wt% GF, however, even with the use of 30 wt% P/N, the V0 value could not be obtained due to the candlewick effect. To resolve this issue, the synergistic effect of P/N and aromatic polycarbodiimide (PCDI) cross-linker or Joncryl epoxy-based chain-extender (CE) on the flame retardancy characteristics of composites was examined. Due to the further chain modification, which also enhances the melt strength of PLA, the dripping of composites in the vertical burning test terminated and the V0 value could be reached when using only 1 wt% PCDI or CE. According to the scanning electron microscopic analysis, the use of noted chain modifiers further homogenized the distribution and refined the particle size of P/N within the PLA matrix. Hence this could synergistically contribute to the enhancements of the fire resistance performance of the PLA composites. Such incorporation of P/N and chain modifiers further leads to the enhancement of the mechanical performance of PLA composites and hence the resultant product can be proposed as a promising durable bioplastic engineering product where fire risk exists.

Synergistic Effects of DOPO-Based Derivative and Organo-Montmorillonite on Flame Retardancy, Thermal Stability and Mechanical Properties of Polypropylene

Polypropylene (PP), as a general thermoplastic polymer, is broadly used in different fields. However, the high flammability, melt dripping and poor mechanical properties of PP are a constraint to the expansion of its applications. In this paper, PP composites containing a combination of a phenethyl-bridged DOPO derivative (PN-DOPO) and organic montmorillonite (OMMT) were prepared via melt blending. The synergistic effects of PN-DOPO and OMMT on the flame retardancy, thermal stability and mechanical properties of PP composites were investigated systematically. The results showed that 20 wt% addition of PN-DOPO with OMMT improved the flame retardancy of PP composites. In particular, the introduction of 17 wt% PN-DOPO and 3 wt% OMMT increased the LOI values of the PP matrix from 17.2% to 23.6%, and the sample reached the V-0 level and reduced the heat release rate and total heat release. TGA indicated that OMMT could improve the thermal stability of the PP/PN-DOPO blends and promote the char residues of PP systems. Rheological behaviour showed a higher storage modulus, loss modulus and complex viscosity of PP/PN-DOPO/OMMT composites, suggesting a more effective network structure. In addition, the tensile strength, flexural properties and impact strength of the PP/PN-DOPO/OMMT composites actually increased for a good dispersion effect. Combined with the char layer analysis, the introduction of OMMT promoted more continuous and compact structural layers containing an aluminium-silicon barrier and phosphorus-containing carbonaceous char in the condensed phase. OMMT can improve the flame retardancy, thermal stability and mechanical properties of PP, and, thus, PN-DOPO/OMMT blends can serve as an efficient synergistic system for flame-retarded PP composites.

Governing effects of melt viscosity on fire performances of polylactide and its fire-retardant systems

Extreme flammability of polylactide (PLA) has restricted its real-world applications. Traditional research only focuses on developing new effective fire retardants for PLA without considering the effect of melt viscosity on its fire performances. To fill the knowledge gap, a series of PLA matrices of varied melt flow index (MFI) with and without fire retardants are chosen to examine how melt viscosity affects its fire performances. Our results show that the MFI has a governing impact on fire performances of pure PLA and its fire-retardant systems if the samples are placed vertically during fire testing. PLA with higher MFI values achieves higher limiting oxygen index (LOI) values, and a lower loading level of fire retardants is required for PLA to pass a UL-94 V-0 rating. This work unveils the correlation between melt viscosity and their fire performance and offers a practical guidance for creating flame retardant PLA to extend its applications.

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The polymer melt viscosity plays a governing role in fire performances of PLA

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PLA with higher MFI shows higher LOI and needs less FR to get the UL-94 V-0

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A critical MFI range of 16.5–29.9 g/10min is found to affect the fire performance

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Melt viscosity does not affect fire performances when PLA was tested horizontally

Progress in Biodegradable Flame Retardant Nano-Biocomposites

This paper summarizes the results obtained in the course of the development of a specific group of biocomposites with high functionality of flame retardancy, which are environmentally acceptable at the same time. Conventional biocomposites have to be altered through different modifications, to be able to respond to the stringent standards and environmental requests of the circular economy. The most commonly produced types of biocomposites are those composed of a biodegradable PLA matrix and plant bast fibres. Despite of numerous positive properties of natural fibres, flammability of plant fibres is one of the most pronounced drawbacks for their wider usage in biocomposites production. Most recent novelties regarding the flame retardancy of nanocomposites are presented, with the accent on the agents of nanosize (nanofillers), which have been chosen as they have low or non-toxic environmental impact, but still offer enhanced flame retardant (FR) properties. The importance of a nanofiller’s geometry and shape (e.g., nanodispersion of nanoclay) and increase in polymer viscosity, on flame retardancy has been stressed. Although metal oxydes are considered the most commonly used nanofillers there are numerous other possibilities presented within the paper. Combinations of clay based nanofillers with other nanosized or microsized FR agents can significantly improve the thermal stability and FR properties of nanocomposite materials. Further research is still needed on optimizing the parameters of FR compounds to meet numerous requirements, from the improvement of thermal and mechanical properties to the biodegradability of the composite products. Presented research initiatives provide genuine new opportunities for manufacturers, consumers and society as a whole to create a new class of bionanocomposite materials with added benefits of environmental improvement.

Combination of Self-Healing Butyl Rubber and Natural Rubber Composites for Improving the Stability

The self-healing composites were prepared from the combination of bromobutyl rubber (BIIR) and natural rubber (NR) blends filled with carbon nanotubes (CNT) and carbon black (CB). To reach the optimized self-healing propagation, the BIIR was modified with ionic liquid (IL) and butylimidazole (IM), and blended with NR using the ratios of 70:30 and 80:20 BIIR:NR. Physical and chemical modifications were confirmed from the mixing torque and attenuated total reflection-fourier transform infrared spectroscopy (ATR-FTIR). It was found that the BIIR/NR-CNT_CB with IL and IM effectively improved the cure properties with enhanced tensile properties relative to pure BIIR/NR blends. For the healed composites, BIIR/NR-CNT_CB-IM exhibited superior mechanical and electrical properties due to the existing ionic linkages in rubber matrix. For the abrasion resistances, puncture stress and electrical recyclability were examined to know the possibility of inner liner applications and Taber abrasion with dynamic mechanical properties were elucidated for tire tread applications. Based on the obtained T_g and Tan δ values, the composites are proposed for tire applications in the future with a simplified preparation procedure.

Nanoreinforcements of Two-Dimensional Nanomaterials for Flame Retardant Polymeric Composites: An Overview

Polymer materials are ubiquitous in daily life. While polymers are often convenient and helpful, their properties often obscure the fire hazards they may pose. Therefore, it is of great significance in terms of safety to study the flame retardant properties of polymers while still maintaining their optimal performance. Current literature shows that although traditional flame retardants can satisfy the requirements of polymer flame retardancy, due to increases in product requirements in industry, including requirements for durability, mechanical properties, and environmental friendliness, it is imperative to develop a new generation of flame retardants. In recent years, the preparation of modified two-dimensional nanomaterials as flame retardants has attracted wide attention in the field. Due to their unique layered structures, two-dimensional nanomaterials can generally improve the mechanical properties of polymers via uniform dispersion, and they can form effective physical barriers in a matrix to improve the thermal stability of polymers. For polymer applications in specialized fields, different two-dimensional nanomaterials have potential conductivity, high thermal conductivity, catalytic activity, and antiultraviolet abilities, which can meet the flame retardant requirements of polymers and allow their use in specific applications. In this review, the current research status of two-dimensional nanomaterials as flame retardants is discussed, as well as a mechanism of how they can be applied for reducing the flammability of polymers.

Development of Flame-Retarded Nanocomposites from Recycled PET Bottles for the Electronics Industry

Recycled polyethylene-terephthalate (rPET) nanocomposites of reduced flammability were prepared by combining aluminum-alkylphosphinate (AlPi) flame retardant (FR) and natural montmorillonite (MMT), in order to demonstrate that durable, technical products can be produced from recycled materials. During the development of the material, by varying the FR content, the ratio and the type of MMTs, rheological, morphological, mechanical and flammability properties of the nanocomposites were comprehensively investigated. Related to the differences between the dispersion and nucleation effect of MMT and organo-modified MMT (oMMT) in rPET matrix, analyzed by Scanning Electron Microscopy (SEM), Energy Dispersive X-Ray Spectroscopy (EDS) and Differential Scanning Calorimetry (DSC), mechanical properties of the nanocomposites changed differently. The flexural strength and modulus were increased more significantly by adding untreated MMT than by the oMMT, however the impact strength was decreased by both types of nanofillers. The use of different type of MMTs resulted in contradictory flammability test result; time-to-ignition (TTI) during cone calorimeter tests decreased when oMMT was added to the rPET, however MMT addition resulted in an increase of the TTI also when combined with 4% FR. The limiting oxygen index (LOI) of the oMMT containing composites decreased independently from the FR content, however, the MMT increased it noticeably. V0 classification according to the UL-94 standard was achieved with as low as 4% FR and 1% MMT content. The applicability of the upgraded recycled material was proved by a pilot experiment, where large-scale electronic parts were produced by injection molding and characterized with respect to the commercially available counterparts.

Preparing the Degradable, Flame-Retardant and Low Dielectric Constant Nanocomposites for Flexible and Miniaturized Electronics with Poly(lactic acid), Nano ZIF-8@GO and Resorcinol Di(phenyl phosphate)

Degradable, flame retardant, and flexible nanocomposite films with low dielectric constant were prepared with poly (lactic acid) (PLA), nano ZIF-8@GO, and degradable flame-retardant resorcinol di(phenyl phosphate) (RDP). The SEM results of the fractured surfaces indicated that ZIF-8@GO and RDP were dispersed uniformly in the PLA matrix. The prepared films had good mechanical properties and the tensile strength of the film with 1.5 wt% of ZIF-8@GO was increased to 48.2 MPa, compared with 38.5 MPa of pure PLA. Meanwhile, the nanocomposite films were flexible due to the toughing effect of RDP. Moreover, above 27.0% of limited oxygen index (LOI) and a VTM-0 rating were achieved for the nanocomposite films. The effects of nano ZIF-8@GO hybrids and RDP on the dielectric properties were investigated, and the results showed that ZIF-8@GO and RDP were beneficial in reducing the dielectric constant and dielectric loss of the nanocomposites.

Advances in Flame Retardant Poly(Lactic Acid)

PLA has become a commodity polymer with wide applications in a number of fields. However, its high flammability with the tendency to flow in fire has limited its viability as a perfect replacement for the petrochemically-engineered plastics. Traditional flame retardants, which may be incorporated into PLA without severely degrading the mechanical properties, are the organo-halogen compounds. Meanwhile, these compounds tend to bioaccumulate and pose a risk to flora and fauna due to their restricted use. Research into PLA flame retardants has largely focused on organic and inorganic compounds for the past few years. Meanwhile, the renewed interest in the development of environmentally sustainable flame retardants (FRs) for PLA has increased significantly in a bid to maintain the integrity of the polymer. A review on the development of new flame retardants for PLA is presented herein. The focus is on metal oxides, phosphorus-based systems, 2D and 1D nanomaterials, hyperbranched polymers, and their combinations, which have been applied for flame retarding PLA are discussed. The paper also reviews briefly the correlation between FR loadings and efficiency for various FR systems, and their effects on processing and mechanical properties.

Structure and Properties Study of PA6 Nanocomposites Flame Retarded by Aluminium Salt of Diisobutylphosphinic Acid and Different Organic Montmorillonites

Two different types of organic montmorillonite, namely quaternary ammonium salt intercalated MMT (CMMT) and quaternary phosphonium salt intercalated MMT (PMMT) were used as fillers in the flame-retardant polyamide (PA6) based on aluminium salts of diisobutylphosphinic acid (ABPA). The influence of different types of organic montmorillonite (OMMT) on the structure and properties of flame-retardant PA6 nanocomposites were systematically investigated. The X-ray diffraction and transmission electron microscopy results suggested that the introduction of OMMT improved the dispersion of the flame retardant particles independently of the type of OMMT. The derivative thermogravimetry (DTG) curve transformed to one peak from two peaks (representing the degradation of ABPA and PA6, respectively) after incorporation of the OMMT, which further confirmed better ABPA dispersion. Viscoelastic measurements demonstrated that a mechanically stable network structure was formed with the introduction of OMMT or ABPA and OMMT, while PA6/ABPA/PMMT presented the highest storage modulus and viscosity, suggesting a more efficient network structure. From UL-94 and limited oxygen index (LOI) tests, PA6/ABPA/PMMT presented the best flame performance, with a UL-94 of V-0 and a LOI of 33%. In addition, the PA6/ABPA/PMMT presented the lowest peak heat release rate (pHRR) among the investigated samples. Combined with the char layer analysis, it can be deduced that the introduction of PMMT improved the dispersion of ABPA, and promoted the formation of more efficient network structure, before promoting more compact char structures, which finally resulted in improved flame retardancy.

Polylactic acid biocomposites: approaches to a completely green flame retarded polymer

Basic paths towards fully green flame retarded kenaf fiber reinforced polylactic acid (K-PLA) biocomposites are compared. Multicomponent flame retardant systems are investigated using an amount of 20 wt% such as Mg(OH)2 (MH), ammonium polyphosphate (APP) and expandable graphite (EG), and combinations with silicon dioxide or layered silicate (LS) nanofillers. Adding kenaf fibers and flame retardants increases the E modulus up to a factor 2, although no compatibilizer was used at all. Thus, in particular adding EG and MH decreases the strength at maximum elongation, and kenaf fibers, MH, and EG are crucial for reducing the elongation to break. The oxygen index is improved by up to 33 vol% compared to 17 vol% for K-PLA. The HB classification of K-PLA in the UL 94 test is outperformed. All flame retarded biocomposites show somewhat lower thermal stability and increased amounts of residue. MH decreases the fire load significantly, and the greatest reduction in peak heat release rate is obtained for K-PLA/15MH/5LS. Synergistic effects are observed between EG and APP (ratio 2:1) in flammability and fire properties. Synergistic multicomponent systems containing EG and APP, or MH with adjuvants offer a promising route to green flame retarded natural fiber reinforced PLA biocomposites.

A novel triazine-rich polymer wrapped MMT: synthesis, characterization and its application in flame-retardant poly(butylene terephthalate)

A novel flame retardant (PTAC–MMT) was successfully prepared by wrapping montmorillonite (MMT) with poly(2,4,6-triallyloxy-1,3,5-triazine) (TAC) via in situ polymerization, and its structure and properties were systematically characterized.