A novel intumescent flame retardant: Synthesis and application in ABS copolymer

Phosphorus-Based Flame-Retardant Acrylonitrile Butadiene Styrene Copolymer with Enhanced Mechanical Properties by Combining Ultrahigh Molecular Weight Silicone Rubber and Ethylene Methyl Acrylate Copolymer

The present work proposes to investigate the effect of an ultrahigh molecular weight silicone rubber (UHMW-SR) and two ethylene methyl acrylate copolymers (EMA) with different methyl acrylate (MA) content on the mechanical and fire performance of a fireproof acrylonitrile butadiene styrene copolymer (ABS) composite, with an optimum amount of ammonium polyphosphate (APP) and aluminum diethyl phosphinate (AlPi). ABS formulations with a global flame retardant weight content of 20 wt.% (ABS P) were melt-compounded, with and without EMA and UHMW-SR, in a Brabender mixer. During this batch process, ABS P formulations with UHMW-SR and/or EMA registered lower torque values than those of ABS P. By means of scanning electron microscopy (SEM), it was possible to observe that all ABS composites exhibited a homogenous structure without phase separation or particle agglomeration. Slightly improved interfacial interaction between the well-dispersed flame-retardant particles in the presence of EMA and/or UHMW-SR was also noticed. Furthermore, synergies in mechanical properties by adding both EMA and UHMW-SR into ABS P were ascertained. An enhancement of molecular mobility that contributed to the softening of ABS P was observed under dynamic mechanical thermal analysis (DMTA). An improvement of its flexibility, ductility and toughness were also registered under three-point-bending trials, and even more remarkable synergies were noticed in Charpy notched impact strength. Particularly, a 212% increase was achieved when 5 wt.% of EMA with 29 wt.% of MA and 2 wt.% of UHMW-SR in ABS P (ABS E29 S P) were added. Thermogravimetric analysis (TGA) showed that the presence of EMA copolymers in ABS P formulations did not interfere with its thermal decomposition, whereas UHMW-SR presence decreased its thermal stability at the beginning of the decomposition. Although the addition of EMA or UHMW-SR, as well as the combination of both in ABS P increased the pHRR in cone calorimetry, UL 94 V-0 classification was maintained for all flame-retarded ABS composites. In addition, through SEM analysis of cone calorimetry sample residue, a more cohesive surface char layer, with Si-O-C network formation confirmed by Fourier transform infrared (FTIR), was shown in ABS P formulations with UHMW-SR.

Bio-Based Phosphate-Containing Polyester for Improvement of Fire Reaction in Wooden Particleboard

A new phosphate-containing bio-polyester based on glycerol and citric acid was synthesized and evaluated as fire-retardant (FR) in wooden particleboards. Phosphorus pentoxide was used to first introduce phosphate esters in the glycerol followed by esterification with citric acid to produce the bio-polyester. The phosphorylated products were characterized by ATR-FTIR, ¹H-NMR and TGA-FTIR. After polyester curing, they were grinded and incorporated in laboratory produced particleboards. The fire reaction performance of the boards was evaluated by cone calorimeter. An increased char residue was produced depending on the phosphorus content and the THR (Total Heat Release), PHRR (Peak of Heat Release Rate) and MAHRE (Maximum Average of the Rate of Heat Emission) were considerably reduced in presence of the FRs. Highlights: Phosphate containing bio-polyester as fire retardant in wooden particle board; Fire performance is improved; Bio-polyester acts in the condensed and gas phases; Additive effectiveness similar to ammonium polyphosphate.

Epoxy Compositions with Reduced Flammability Based on DER-354 Resin and a Curing Agent Containing Aminophosphazenes Synthesized in Bulk Isophoronediamine

A method for the synthesis of an amine-containing epoxy resin curing agent by dissolving hexakis-[(4-formyl)phenoxy]cyclotriphosphazene in an excess of isophoronediamine was developed. The curing agent was characterized via NMR and IR spectroscopy and MALDI-TOF mass spectrometry, and its rheological characteristics were studied. Compositions based on DER-354 epoxy resin and the synthesized curing agent with different amounts of phosphazene content were obtained. The rheological characteristics of these compositions were studied, followed by their curing. An improvement in several thermal (DSC), mechanical (compression, tension, and adhesion), and physicochemical (water absorption and water solubility) characteristics, as well as the fire resistance of the obtained materials modified with phosphazene, was observed, compared with unmodified samples. In particular, there was an improvement in adhesive characteristics and fire resistance. Thus, compositions based on a curing agent containing a 30% modifier were shown to fulfill the V-1 fire resistance category. The developed compositions can be processed by contact molding, winding, and resin transfer molding (RTM), and the resulting material is suitable for use in aircraft, automotive products, design applications, and home repairs.

Inherent Flame-Retardant, Humid Environment Stable and Blue Luminescent Polyamide Elastomer Regulated by Siloxane Moiety

The rapid development of the polymeric materials market has created an urgent demand for the thermoplastic polyamide elastomer (TPAE) owing to its greater functionality, and ability to be synthesized via a facile and industrial route. In this work, a series of novel silicone-containing polyamides (PA1212/Si12) were successfully synthesized from 1,12-dodecarboxylic acid (LA), 1,12-dodecarbondiamine (DMDA), and 1,3-bis (amino-propyl) tetramethyldisiloxane (BATS), via a one-pot melt polycondensation method in the absence of a catalyst. FTIR, ¹H-NMR, GPC and inherent viscosity results cohesively prove that the polymerization of monomers was well conducted, and the chemical structure was in high accordance with the design. As expected, the Si12 unit-content of the copolymers regulate the properties of the series. As the feeding ratio of BATS in the diamines increases from 5 mol% to 40 mol%, the thermal transition temperatures, T_g and T_m, decline steadily before finally stabilizing at ~6 °C and 160 °C, respectively, indicating that the co-polyamides possess improved chain flexibility but restricted crystallization ability. The conspicuous evolution in crystalline morphology of the series was observed by XRD and AFM. The increased PA Si12 phase induces the crystallized PA 1212 phase to transit from a thermally-favorable large and rigid crystal structure (α phase) to a kinetically-favorable small and ductile crystal structure (γ phase). Reflected in their stress–strain behavior, PA1212/Si12 copolymers are successfully tailored from rigid plastic to ductile elastomer. The tensile strength mildly drops from above 40 MPa to ~30 MPa while the reversible elongation increases from ~50% to approximately 350%. Accordingly, the moderate surface tension differences in the monomers facilitate the efficient conduction of the co-polymerization process, and the distributed short siloxane unit in the backbone fulfills the copolymer with desirable elasticity. Interestingly, the novel silicone-containing polyamides also display Si12 unit-content dependent flame retardancy, humidity stability, and unconventional solid-state fluorescence properties. The elastomers exhibit a low bibulous rate and anti-fouling characteristics to dye droplets and mud contamination, pass the V–1 rating (UL 94) with a constantly declining PHRR value, and emit blue luminescence under a 365 nm light source. Herein, we propose a new facile strategy for developing a high-performance and multifunctional silicone-modified polyamide, which bears promising industrialization potential. In addition, this first reported silicone-containing thermoplastic polyamide elastomer, which is self-extinguishing, anti-fouling and blue-luminescent, will further broaden the application potential of thermoplastic polyamide elastomers.

A functional lignin-based nanofiller for flame-retardant blend

Lignin-based flame retardants represent great promising next-generation flame retardants due to their sustainability, unique aromatic structure, and high charring capability. However, their applications are still limited by the compatibility, processability, and efficiency of flame retardancy. Here, a green functional lignin-based nanofiller (lignin-diethylenetriamine/red phosphorus nanoparticles, Lignin-N-P NPs) was prepared by the chemical modification and co-precipitation. After blending with the commercial acrylonitrile butadiene styrene copolymers (ABS), the physical, chemical, and flame retardant properties of the blends reveal that Lignin-N-P NPs/ABS blend has acceptable processability, mechanical properties, and significantly improved thermal stability and fire performance. Its values of peak heat release rate and total heat released per unit area were significantly dropped 67.8% and 77.5%, respectively. This study will initiate a new design for not only flame retardants but also lignin-based materials.

Carbon Nanotube-Based Composite Filaments for 3D Printing of Structural and Conductive Elements

In this publication, we describe the process of fabrication and the analysis of the properties of nanocomposite filaments based on carbon nanotubes and acrylonitrile butadiene styrene (ABS) polymer for fused deposition modeling (FDM) additive manufacturing. Polymer granulate was mixed and extruded with a filling fraction of 0.99, 1.96, 4.76, 9.09 wt.% of CNTs (carbon nanotubes) to fabricate composite filaments with a diameter of 1.75 mm. Detailed mechanical and electrical investigations of printed test samples were performed. The results demonstrate that CNT content has a significant influence on mechanical properties and electrical conductivity of printed samples. Printed samples obtained from high CNT content composites exhibited an improvement in the tensile strength by 12.6%. Measurements of nanocomposites’ electrical properties exhibited non-linear relation between the supply voltage and measured sample resistivity. This effect can be attributed to the semiconductor nature of the CNT functional phase and the occurrence of a tunnelling effect in percolation network. Detailed I–V characteristics related to the amount of CNTs in the composite and the supply voltage influence are also presented. At a constant voltage value, the average resistivity of the printed elements is 2.5 Ωm for 4.76 wt.% CNT and 0.15 Ωm for 9.09 wt.% CNT, respectively. These results demonstrate that ABS/CNT composites are a promising functional material for FDM additive fabrication of structural elements, but also structural electronics and sensors.

Synthesis of a Novel Spirocyclic Inflatable Flame Retardant and Its Application in Epoxy Composites

Derivatives of 3,9-dichloro-2,4,8,10-tetraoxa-3,9-diphosphaspiro-[5,5]undecane-3,9-dioxide (SPDPC) are of increasing interest as flame retardants for polymeric materials. In addition, SPDPC is also an important intermediate for the preparation of intumescent flame retardants (IFRs). However, low efficiency and undesirable dispersion are two major problems that seriously restrain the application of IFRs as appropriate flame retardants for polymer materials. Usually, the functionalization or modification of SPDPC is crucial to acquiring high-performance polymer composites. Here, a small molecule spirocyclic flame retardant diphenylimidazole spirocyclic pentaerythritol bisphosphonate (PIPC) was successfully prepared through the substitution reaction between previously synthesized intermediate SPDPC and 2-phenylimidazole (PIM). Phenyl group and imidazole group were uniformly anchored on the molecular structure of SPDPC. This kind of more uniform distribution of flame retardant groups within the epoxy matrix resulted in a synergistic flame retardant effect and enhanced the strength of char layers to the epoxy composites, when compared to the unmodified epoxy. The sample reached a limiting oxygen index (LOI) of 29.7% and passed with a V-0 rating in the UL 94 test with the incorporation of only 5 wt % of as-prepared flame retardant PIPC. Moreover, its peak of heat release rate (pHRR) and total heat release (THR) decreased by 41.15% and 21.64% in a cone calorimeter test, respectively. Furthermore, the addition of PIPC has only slightly impacted the mechanical properties of epoxy composites with a low loading.

Synthesis and characterization of SPDSCD and its flame retardant application on epoxy resins

In this study, a flame retardant agent, 2,4,8,10-tetraoxo-3,9-diphosphospiro[5.5]undecane spirophosphate-4,4-diaminopair benzene disulfone-1,3,5-himetriazine (SPDSCD), is synthesized through a direct polycondensation reaction. SPDSCD is a chemically expanded phosphorus-containing flame retardant in epoxy resins (EP). The molecular structure of SPDSCD and thermal stability are characterized by nuclear magnetic resonance, Fourier transform infrared spectroscopy, and thermogravimetric analysis, and EP/SPDSCD composites were investigated in detail. These properties are associated with the phosphorus-containing spiro structure on the main molecular chain which can promote condensation polymerization into carbon during pyrolysis, the new nitrogen-containing carbon source, and the triazine structure. SPDSCD shows good thermal stability and low flammability, the weight loss from 500 to 800 °C was only 6.1 wt%, and the residual mass at 800 °C was 48.9 wt%. With the addition of SPDSCD, the flame retardant quality of the composites was gradually enhanced, the carbon residue becomes denser, which isolates heat transfer and inhibits the volatilization of flue gas. The addition of 20 wt% SPDSCD in the EP sample was associated with a limited oxygen index (LOI) value of 26% and a vertical burning V-0 rating. Cone calorimeter test shows that the peak heat release rate is reduced by 75%; the heat release rate curve enters the heat release platform area with a value lower than the first peak, TSP is reduced by 24%, the ac-CO₂Y value reduced by 25.6%, indicating that SPDSCD/EP produced less CO₂, which obviously prevented the combustion of volatile gas. SPDSCD exerted a charring and barrier effect in the condensation phase. Using basic characterization and flame retardancy testing, this work determined that SPDSCD has good flame retardancy when added to EP.

In this study, a flame retardant agent, 2,4,8,10-tetraoxo-3,9-diphosphospiro[5.5]undecane spirophosphate-4,4-diaminopair benzene disulfone-1,3,5-himetriazine (SPDSCD), is synthesized through a direct polycondensation reaction.

The application of a phosphorus nitrogen flame retardant curing agent in epoxy resin

In order to improve the compatibility of flame retardant and epoxy resin, a phosphorus nitrogen flame retardant curing agent poly(p-xylylenediamine spirocyclic pentaerythritol bisphosphonate) (PPXSPB) was synthesized. FTIR, 1HNMR, and mass spectroscopy were used to identify the chemical structure of PPXSPB. Epoxy resin (E-44) and PPXSPB as the raw material, a series of thermosetting systems were prepared. The effects of PPXSPB on flame retardancy, water resistance, thermal degradation behavior, mechanical properties and the adhesive strength of EP/PPXSPB thermosets were investigated. The results show that with the increase of phosphorus content, the oxygen index and carbon residue of the system both increased significantly, and the heat release rate gradually decreased, which is of great significance in delaying the occurrence of fire. When the phosphorus content is 3.24% in EP/PPXSPB thermosets, EP-2 can successfully pass the UL94 V-0 flammability rating, the LOI value of EP-2 can reach 31.4%, the impact strength and tensile strength was 6.58 kJ/m2 and 47.10 MPa respectively, and the adhesive strength was 13.79 MPa, the system presents a good overall performance.

Comparative Studies on Thermal, Mechanical, and Flame Retardant Properties of PBT Nanocomposites via Different Oxidation State Phosphorus-Containing Agents Modified Amino-CNTs

High-performance poly(1,4-butylene terephthalate) (PBT) nanocomposites have been developed via the consideration of phosphorus-containing agents and amino-carbon nanotube (A-CNT). One-pot functionalization method has been adopted to prepare functionalized CNTs via the reaction between A-CNT and different oxidation state phosphorus-containing agents, including chlorodiphenylphosphine (DPP-Cl), diphenylphosphinic chloride (DPP(O)-Cl), and diphenyl phosphoryl chloride (DPP(O₃)-Cl). These functionalized CNTs, DPP(Ox)-A-CNTs (x = 0, 1, 3), were, respectively, mixed with PBT to obtain the CNT-based polymer nanocomposites through a melt blending method. Scanning electron microscope observations demonstrated that DPP(Ox)-A-CNT nanoadditives were homogeneously distributed within PBT matrix compared to A-CNT. The incorporation of DPP(Ox)-A-CNT improved the thermal stability of PBT. Moreover, PBT/DPP(O₃)-A-CNT showed the highest crystallization temperature and tensile strength, due to the superior dispersion and interfacial interactions between DPP(O₃)-A-CNT and PBT. PBT/DPP(O)-A-CNT exhibited the best flame retardancy resulting from the excellent carbonization effect. The radicals generated from decomposed polymer were effectively trapped by DPP(O)-A-CNT, leading to the reduction of heat release rate, smoke production rate, carbon dioxide and carbon monoxide release during cone calorimeter tests.

Synthesis of a novel polyphosphate and its application with APP in flame retardant PLA

A phosphorus-containing flame retardant was synthesized via an A₂ + B₃ type reaction of bisphenolic acid-based monomer and phosphorus oxychloride. Then, intumescent flame retardant systems were prepared by combining PFRS with ammonium polyphosphate.

Synthesis of a lignin-based phosphorus-containing flame retardant and its application in polyurethane

In this work, new lignin-based flame retardant LHDs were successfully synthesized through the reaction between lignin, 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) and hexamethylene diisocyanate (HDI). The chemical structure of LHD was characterized by FTIR, ¹H NMR, ³¹P NMR. The thermal stability of LHD was studied by TGA. The results showed that the residual carbon content of L15HD (15% of lignin in LHD) at 600 °C reached 16.55%, indicating that this prepared flame retardant can be a type of good char forming agent. LHDs were then applied to prepare flame-retardant lignin-based polyurethane (FLPU). Lignin-based polyurethane (LPU) was synthesized by the reaction between lignin, polyethylene glycol 200 (PEG 200) and hexamethylene diisocyanate (HDI). The limiting oxygen index (LOI) value of the FLPU reached 30.2% when the addition content of L15HD (15% lignin in LHD) in L₂₀PU (20% lignin in LPU) was 25%, exhibiting excellent flame-retardant properties. Scanning electron microscopy (SEM) analysis of the FLPU char residual showed that there was a continuous dense outer carbon layer on the residue surface, and the inner carbon layer had many expansion bubbles, indicating the LHDs have an excellent flame retardant effect for PU. In addition, FLPU presented better hardness and adhesion than PU. The hardness of F_L15-25L₂₀PU (lignin content in LPU was 20%, and added content of L15HD in LPU was 25%) reached 4H, and its adhesion was 0. These excellent properties illustrated that the LHDs are ideal flame retardants and reinforcing agents for LPU because of the co-curing and strong interface between LHD and LPU.

In this work, new lignin-based flame retardant LHDs were successfully synthesized through the reaction between lignin, 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) and hexamethylene diisocyanate (HDI).

Direct Access to Functional (Meth)acrylate Copolymers through Transesterification with Lithium Alkoxides

A straightforward and efficient synthetic method that transforms poly(methyl methacrylate) (PMMA) into value-added materials is presented. Specifically, PMMA is modified by transesterification to produce a variety of functional copolymers from a single starting material. Key to the reaction is the use of lithium alkoxides, prepared by treatment of primary alcohols with LDA, to displace the methyl esters. Under optimized conditions, up to 65% functionalization was achieved and copolymers containing alkyl, alkene, alkyne, benzyl, and (poly)ether side groups could be prepared. The versatility of this protocol was further demonstrated through the functionalization of both PMMA homo and block copolymers obtained through either radical polymerization (traditional and controlled) or anionic procedures. The scope of this strategy was illustrated by extension to a range of architectures and polymer backbones.

Functionalized Carbon Nanotubes with Phosphorus- and Nitrogen-Containing Agents: Effective Reinforcer for Thermal, Mechanical, and Flame-Retardant Properties of Polystyrene Nanocomposites

Aminated multiwalled carbon nanotubes (A-MWCNT) were reacted with diphenylphosphinic chloride (DPP-Cl) to prepare the functionalized MWCNT (DPPA-MWCNT). A-MWCNT and DPPA-MWCNT were respectively mixed with polystyrene (PS) to obtain composites through the melt compounding method. SEM observations demonstrated that the DPPA-MWCNT nanofillers were more uniformly distributed within the PS matrix than A-MWCNT. PS/DPPA-MWCNT showed improved thermal stability, glass transition temperature, and tensile strength in comparison with PS/A-MWCNT, resulting from good dispersion and interfacial interactions between DPPA-MWCNT and PS matrix. The incorporation of DPPA-MWCNT to PS significantly reduced peak heat release rate, smoke production rate, and carbon monoxide and carbon dioxide release in cone calorimeter tests. The enhanced fire-retardant properties should be ascribed to the barrier effect of carbon nanotubes, which could provide enough time for DPPA-MWCNT and its functionalized groups to trap the degrading polymer radicals to catalyze char formation. The char layer served as an efficient insulating barrier to reduce the exposure of polymer matrix to an external heat source as well as retarding the flammable gases from feeding the flame.

Fabrication and origin of flame retarding glass fiber/bismaleimide resin composites with high thermal stability, good mechanical properties, and a low dielectric constant and loss for high frequency copper clad laminates

High performance glass fiber reinforced resin composites were fabricated by designing structures of fiber and resin with unique hyperbranched polysiloxane.

An inherently flame-retardant polyamide containing a phosphorus pendent group prepared by interfacial polymerization

Inherent flame retardation has the advantage that it will allow polymers to impart the flame retardancy permanently, and the introduction of a few weight percent of the flame retardant unit can lead to improvements in the overall flame retardancy.

Synthesis and properties of a new halogen-free flame-retardant epoxy resin curing agent

A novel intumescent flame-retardant curing agent, poly-( meta-xylylenediamine spirocyclic pentaerythritol bisphosphonate) (PMXSPB), was synthesized and subsequently characterized using Fourier transform infrared, proton nuclear magnetic resonance, and mass spectroscopies. PMXSPB was used as a flame-retardant and curing agent for preparing halogen-free flame-retarded epoxy (EP) resins. The thermal stability, mechanical properties, flame resistance, and morphology of the char layer of flame-retarded EP resins were investigated using thermogravimetric analysis, tensile and Charpy impact tests, limiting oxygen index (LOI), the UL94 test, and scanning electron microscopy, respectively. The results demonstrated that the addition of PMXSPB improved the flame resistance of EP resin composites, and the residual char ratio at 600°C was significantly increased. The flame-retarded composites filling with 3.01% phosphorus content (EP 100 g and PMXSPB 35 g) exhibited the best combination of properties, including a higher glass transition temperature (147°C), good thermal stability, an initial weight loss temperature of 269°C, and an LOI of 31.2. The vertical burning test reached the UL94 V-0 level, and the tensile and impact strengths were 51 MPa and 4.8 kJ m−2, respectively.

Synthesis and characterization of a cyclic 9,9-bis(4-hydroxyphenyl)fluorine (phenylene phosphonate) oligomer and its flame retardancy application

A novel solid flame retardant cyclic 9,9-bis(4-hydroxyphenyl)fluorine (phenylene phosphonate) (CPFP) oligomer was synthesized in high yields by the reaction of phenylphosphonic dichloride with 9,9-bis(4-hydroxyphenyl)fluorine under pseudo-high-dilution conditions.

Formation of self-extinguishing flame retardant biobased coating on cotton fabrics via Layer-by-Layer assembly of chitin derivatives

The self-extinguishing coating, consisting of biobased chitin derivatives, phosphorylated chitin and deacetylated chitin (chitosan), was deposited on cotton fabrics via the Layer-by-Layer (LbL) assembled method. The content of phosphorylated chitin prepared on cotton fabrics surface is dependent on the bilayers' number and concentration of phosphorylated chitin. In the vertical flame test, the cotton fabric with 20 bilayers prepared at the high phosphorylated chitin concentration (2 wt%) could extinguish the flame. Microcombustion calorimetry result showed that all coated cotton fabrics showed lower peak heat-release rate and total heat-release values compared with that of the pure one. Thermogravimetric analysis result indicated that thermal and thermal oxidation stability of all coated cotton fabrics were enhanced in the high temperature range (400-700°C). This work provided the flame retardant multilayer films based on fully biobased chitin derivatives on cotton fabrics to enhance its flame retardancy.