Silicon-containing flame retardant epoxy resins: Synthesis, characterization and properties

Ultra-High-Temperature Ceramic-Doped Inorganic Polymers for Thermo-Structural Fiber-Reinforced Composites

New inorganic nanostructured matrices for fiber-reinforced composites with enhanced high-temperature stability were developed from alkali aluminosilicate polymers doped with different ultra-high-temperature ceramic (UHTC) particles. The alkali aluminosilicate matrices were synthesized at room temperature with a high SiO2:Al2O3 ratio and then further functionalized by doping with 4-5 wt % of micrometric SiC, ZrB2, ZrC, and HfC powders and finally thermally stabilized as glass-ceramics at 750 °C. The different UHTC-doped matrices were characterized according to their dimensional and microstructural changes after thermal cycling in air flux at 1000 °C. The first results showed that carbide-based UHTC powders improved the thermal stability of the matrices, preventing the excessive swelling of the material and the formation of detrimental voids that might result in the lack of adhesion with reinforcing fibers. Contrarily, the addition of ZrB2 resulted in an excessive matrix swelling at high temperature, thus proving no efficacy compared to the undoped matrix. Impregnation tests carried out on C-fiber fabrics showed good processability, adhesion to the fibers, and fracture pull-out, especially for carbide-based matrices.

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.

Synthesis of SiO2 Nanoparticle Epoxy Resin Composite and Silicone-Containing Epoxy Resin for Coatings

Due to its unique properties, including strong adhesion force, high heat resistivity, high insulation properties, and strong mechanical properties, epoxy resin is the most commonly used material for a variety of applications, including adhesives, electronic devices for coatings, and somewhere as a matrix for reinforcement of composites as a fiber network. To boost their properties, different other materials are also inserted in their structure and made its composites; silicon is one of them. Corrosion is serious for marine equipment and causes economic loss. To overcome such issues, different types of coating materials are developed. In this review, current methods for coatings of different materials using a silicon dioxide epoxy nanocomposite are discussed in diversity with the currently followed synthetic routes for the preparation of nanosilica epoxy composites and enhanced properties.

Barrier Effects of Cellulosic Fibers with Hybrid Coating Based on Zirconium Metal-Organic Framework

Metal-organic frameworks (MOFs) have great potential for the development of fire barriers for flammable materials. Accordingly, zirconium-based metal-organic framework (Zr-MOF), branched polyethyleneimine (BPEI), and vinyltriethoxysilane (VTES) were deposited to produce composites assembled on cellulosic fibers to investigate their barrier effects. The structure, morphology, and thermal properties of the cellulosic fibers were characterized using FTIR spectroscopy, SEM, and TGA. Compared with the untreated cotton sample, the temperature of the maximum rate of weight loss (T_max) of C-Zr-MOF/BPEI/VTES increased from 479 to 523.3 °C and the maximum weight loss rate (R_max) at T_max decreased from 37.6 to 17.2 wt%/min. At 800 °C, the pristine cotton was burned out without residues whereas the residual char content of the C-Zr-MOF/BPEI/VTES sample was 7.2355 wt%. From the vertical burning tests, the results suggested that the C-Zr-MOF/BPEI/VTES sample had better barrier effects by reducing the flame-spread speed and generating more protective char layers.

Use of a Mixture of Polyols Based on Metasilicic Acid and Recycled PLA for Synthesis of Rigid Polyurethane Foams Susceptible to Biodegradation

Two polyol raw materials were obtained in the conducted research, one based on metasilicic acid (MSA), the other based on poly(lactic acid) (PLA) waste. The obtained polyols were characterized in terms of their applicability for the production of rigid polyurethane foams (RPUFs). Their basic analytical properties (hydroxyl number, acid number, elemental analysis) and physicochemical properties (density, viscosity) were determined. The assumed chemical structure of the obtained new compounds was confirmed by performing FTIR and ¹H NMR spectroscopic tests. Formulations for the synthesis of RPUFs were developed on the basis of the obtained research results. A mixture of polyols based on MSA and PLA in a weight ratio of 1:1 was used as the polyol component in the polyurethane formulation. The reference foam in these tests was a foam that was synthesized only on the basis of MSA-polyol. The obtained RPUFs were tested for basic functional properties (apparent density, compressive strength, water absorption, thermal conductivity coefficient etc.). Susceptibility to biodegradation in soil environment was also tested. It was found that the use of mixture of polyols based on MSA and PLA positively affected the properties of the obtained foam. The polyurethane foam based on this polyol mixture showed good thermal resistance and significantly reduced flammability in comparison with the foam based MSA-polyol. Moreover, it showed higher compressive strength, lower thermal conductivity and biodegradability in soil. The results of the conducted tests confirmed that the new foam was characterized by very good performance properties. In addition, this research provides information on new waste management opportunities and fits into the doctrine of sustainable resource management offered by the circular economy.

Synthesis of Silicon Hybrid Phenolic Resins with High Si-Content and Nanoscale Phase Separation Structure

In this paper, a set of silicon hybrid phenolic resins (SPF) with high Si-content were prepared by mixing phenolic resins with self-synthesized silicon resins. In order to obtain the nanoscale phase structure, condensation degree and the amount of Si-OH groups in silicon resins were controlled by the amount of inhibitor ethanol in the hydrolytic condensation polymerization of siloxane. Increasing the amount of ethanol resulted in more silanol groups and a lower degree of condensation for silicon resins, which then led to more formation of Si-O-Ph bonds in hybrid resin and improved compatibility between silicon resin and phenolic resin. When 400% ethanol by weight of siloxane was used in the sample SPF-4, nanoscale phase separation resulted. The residual weight of the cured SPF-4 at 1000 °C (R1000) significantly increased compared to pure phenolic resins. The result of the oxyacetylene flame ablation and the Cone Calorimeter test confirmed the improved ablative property and flammability after the modification. The performance improvement of the cured SPF-4 was attributed to the nanoscale phase structure and high silicon content, which promoted the formation of dense silica protective layers during pyrolysis.

Facile synthesis of aluminum branched oligo(phenylphosphonate) submicro-particles with enhanced flame retardance and smoke toxicity suppression for epoxy resin composites

A novel and submicro-scale aluminum branched oligo(phenylphosphonate) (AHPP) has been successfully synthesized and embedded into a polymeric substrate to improve the fire safety of epoxy resin (EP). The chemical structures of intermediates and target products were characterized using the nuclear magnetic resonance spectroscopy, X-ray diffraction and Fourier transform infrared analysis. Morphology analysis confirmed that all of the as-synthesized AHPP submicro-particles are mutually well-separated. Combustion results demonstrated that the limiting oxygen index value is increased to 30.5% from 23.5% while the PHRR and THR are decreased by ca. 68.1% and 41.2%, respectively for the EP/AHPP-7.5 composite compared to the corresponding values for pure EP. In addition, the binary blends display the satisfying smoke toxicity suppression performance during combustion. The total smoke production and the total CO yield for EP/AHPP-7.5 are dramatically reduced by 62.0% and 32.3%, respectively, which may mainly be ascribed to the catalytic carbonization performance of the polymers and formation of Al₂O₃ layers on the surface of the char residues. As a result, the findings in this study enabled the submicro-scale phosphorus-containing flame retardant to be a potential candidate as an efficient additive for reducing smoke toxicity of polymer composites.

Polyurethane foams with 1,3,5-triazine ring, boron and silicon

The method of obtaining polyurethane foams with 1,3,5-triazine ring and silicon and boron atoms, based on two oligoetherols, the one, synthesized from melamine diborate and propylene carbonate and the second, obtained from metasilicic acid, glycidol and ethylene carbonate, was elaborated. The physical properties of polyurethane foams were tested depending on composition of oligoetherol substrates mixture used. Obtained polyurethane foams have high compression strength and enhanced thermal resistance in comparison to classic rigid polyurethane foams. Long-term thermal exposure at 150–175°C results in increase of compression strength and reducing in flammability. The polyurethane foams exposed per month at 150°C show increase of oxygen index within 24.4–27.6, i.e. they are self-extinguishing. When polyurethane foams are exposed at 175°C, the oxygen index rise into 46.5–48.0, and the materials become non-flammable.

Novel flame retardancy effect of phenethyl-bridged DOPO derivative on epoxy resin

A series of flame-retardant epoxy resins (EPs) containing either phenethyl-bridged 9 or 10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide derivative (bisDOPO) were prepared. The flame-retardant properties of bisDOPO on EP composites were characterized by the limiting oxygen index (LOI), the UL-94 vertical burning, and the cone calorimeter test (CCT).The LOI of the EP/bisDOPO composites increased from 21.8% to 38.0%, and the hybrids with the 10 wt% bisDOPO obtained a V-0 rating in the UL94 vertical burning test. The char residue following the CCT showed intumescent structures with continuous and compact surfaces that can effectively suppress the spread of the flame and extinguish the fire. This was confirmed through both visual observation and scanning electron microscopy (SEM) measurements. The flame-retardant mechanism was studied by Fourier transform infrared spectroscope (FTIR), thermogravimetric analysis/infrared spectrometry, SEM/energy-dispersive X-ray, and pyrolysis-gas chromatography/mass spectrometry. Overall, bisDOPO was an effective flame retardant with potential applications within EP.

Preparation, characterization, and properties of organic silicone intermediate-modified epoxy resin copolymers

In this work, a series of silicone-containing epoxy copolymers (E231) were synthesized through a condensation reaction between the Si-OCH3 of SY231 and the –OH of E51. The chemical structural determinations of the copolymer were carried out with the Fourier transform infrared spectroscopy, nuclear magnetic resonance (NMR), and an epoxy equivalent weight test. Besides, the grafting content of SY231 in E231 copolymers was determined by the proton (1H) NMR integration technique. The mechanical properties, thermal stabilities, and morphology of impact fractured surface of cured products were also investigated. The experimental results show that increased impact strength was observed for the cured E231 products, meanwhile the improvement of the impact strength was closely related to the content of silicone in copolymers. A smooth surface was observed on the neat epoxy specimen, while a rough surface was observed by scanning electron microscopic examination on the impact fractured surface of the cured E231 products. The data of TGA indicated that silicone exerted its thermal stability through thermal decomposition energy dissipation, acted as thermal insulation, and finally enhanced the solid residue at 800°C. Dynamic thermomechanical analysis tests displayed that the glass transition temperature of epoxy systems decreased slightly with the introduction of the flexible organosilicone.

Synergistic flame retardant properties of a layered double hydroxide in combination with zirconium phosphonate in polypropylene

High-performance flame retardant nanocomposites were prepared for polypropylene (PP).

Novolac cured epoxy resin/fullerene modified clay composites: applied to copper clad laminates

Schematic representation of modified clay material, epoxy composite exfoliated and intercalated morphologies and its burning behavior.

Preparation and properties of epoxy resin composites containing hexaphenoxycyclotriphosphazene

Hexaphenoxycyclotriphosphazene (HPCTP) was synthesized by a nucleophilic substitution reaction between hexachlorocyclotriphosphazene and phenol. The chemical structure of HPCTP was then characterized by Fourier transform infrared spectroscopy as well as 1H and 31P nuclear magnetic resonance spectroscopy. The synthesized HPCTP was incorporated into the diglycidyl ether of bisphenol A to prepare epoxy resin (EP) composites using 4,4′-diamino diphenylmethane as curing agent. The thermal and flame-retardant properties of cured samples were investigated by differential scanning calorimetry, thermogravimetric analysis, UL-94 vertical burning test, and cone calorimetry. Evaluation of thermal properties demonstrated that the resulting composites achieved high thermal stability with high char yields. The UL-94 V-0 rating was easily achieved with the addition of HPCTP, and the heat release intensity simultaneously decreased. Results of scanning electron microscopy and energy-dispersive x-ray spectroscopy confirmed that HPCTP can enhance the thermal stability and flame retardancy of epoxy resin.