Synthesis of aromatic–aliphatic polyamide acting as adjuvant in polylactic acid (PLA)/ammonium polyphosphate (APP) system

Synthesis of P-/N-Containing Bamboo-Activated Carbon toward Enhanced Thermal Stability and Flame Retardancy of Polylactic Acid

A P-/N-containing bamboo-activated carbon (BACm) was successfully synthesized by steam activation of bamboo charcoal and chemical grafting to as-prepared activated carbon using the reaction of phosphoric acid and urea. Characterizations of BACm presented a synergistic grafting of P and N elements to the BAC surface. The BACm was further loaded in a polylactic acid (PLA) matrix to prepare BACm/PLA composites. Mechanical strength study showed tensile strength dropped from 75.19 MPa to 61.30 MPa, and tensile modulus from 602.49 MPa to 375.56 MPa, suggesting a rigidity reduction and deformation resistance enhancement owing to the roughened surface of BACm that interlocked with the polymer. The thermogravimetric analysis showed that the carbon residue rate of BACm dramatically fell to 49.25 wt.% in contrast to 88.28% for the control BAC, and cone calorimeter measurements confirmed the enhancement of flame retardancy of the composites with BACm loading, and the carbon residue rate increased progressively with BACm loading in the composites, notably up to 8.60 wt.% for the BAC/PLA9 composite, which outweighed the theoretical residue rate by more than 50%. The elemental analysis also confirmed rich P/N levels of the dense carbon residue layer that could perform synergistically and effectively in fire suppression. The BACm tended to stimulate the earlier decomposition of the composites and formed a continuous residual carbon layer which functioned as an effective barrier hindering the mass and heat transfer between the combustion zone and the underlying matrix. Moreover, 9 wt.% of BACm loading could attain a V-0 rating (UL94) for the composite with an improved limiting oxygen index up to 31.7%. The biomass-based modified activated carbon in this work could be considered as an alternative flame retardant in polymer applications.

Sensitivity Analysis of a Bench-Scale Pyrolysis Model for Composite Materials: A Case Study of Poly(lactic acid)/Melamine/Ammonium Polyphosphate

On the basis of a well-developed bench-scale pyrolysis model that relates material composition to flammability, this paper applied mathematical simulations to explore the model sensitivity for the prediction of fire behavior of composite materials. A pyrolysis model for poly(lactic acid) blended with melamine and ammonium polyphosphate as the reference material was selected as the case for analysis. The model input parameters for simulations include the heat of reaction, apparent activation energy, and pre-exponential factor of 15 reactions, as well as the thermal conductivity, emissivity coefficient, absorption coefficient, and density of 17 condensed-phase components. Each reaction-related or component-related parameter was adjusted from 80% of the model value to 120% with a 5% or 10% gradient. Finally, 826 simulation cases in total were calculated for analysis. Both the mass loss rate and the heat release rate of each case were calculated to characterize the sensitivity, which showed the same pattern. Finally, seven primary reactions and five key condensed-phase components with high sensitivity were identified. The predicted fire behaviors are highly related to the kinetics of the reactions between virgin components or reactions where virgin components play an important role in, including the pyrolysis of melted poly(lactic acid), the first step in the pyrolysis of melamine, the first step in the pyrolysis of ammonium polyphosphate, the reaction between melted poly(lactic acid) and melamine, the reaction between ammonium polyphosphate and melamine, and further decomposition of the generated new condensed-phase component. Particularly, the activation energy of these reactions is of sensitivity larger than 5% or 15%. The heat of decomposition of pyrolysis of melted poly(lactic acid) also showed a sensitivity of 2%-5%. The pre-exponential factor of all reactions showed a sensitivity of less than 2%, which can be ignored. Inputting the proper density is important for the prediction of fire behavior as the sensitivity is larger than 2%. The sensitivity of the milligram-scale model was also processed and compared. These simulations provided a fundamental understanding of the sensitivity of thermophysical and chemical properties and thus provide advanced insights into fire behavior modeling and new composite material design.

The Efficiency of Biobased Carbonization Agent and Intumescent Flame Retardant on Flame Retardancy of Biopolymer Composites and Investigation of their Melt-Spinnability

The objective of this study is to assess the efficiency of biobased carbonization agent in intumescent formulations (IFRs) to examine the flame retardant properties of polylactic acid (PLA) composites and to investigate their melt-spinnability. We used phosphorous-based halogen free flame retardant (FR) and kraft lignin (KL) as bio-based carbonization agent. After melt compounding and molding into sheets by hot pressing various fire related characteristics of IFR composites were inspected and were characterized by different characterization methods. It was fascinating to discover that the introduction of 5–20 wt% FR increased the limiting oxygen index (LOI) of PLA composites from 20.1% to 23.2–33.5%. The addition of KL with content of 3–5 wt% further increased the LOI up to 36.6–37.8% and also endowed PLA/FR/KL composites with improved anti-dripping properties. Cone calorimetry revealed a 50% reduction in the peak heat release rate of the IFR composites in comparison to 100% PLA and confirmed the development of an intumescent char structure containing residue up to 40%. For comparative study, IFR composites containing pentaerythritol (PER) as a carbonization agent were also prepared and their FR properties were compared. IFR composites were melt spun and mechanical properties of multifilament yarns were tested. The analysis of char residues by energy dispersive X-ray spectrometry (EDS) and SEM images confirmed that PLA/FR/KL composites developed a thicker and more homogeneous char layer with better flame retardant properties confirming that the fire properties of PLA can be enhanced by using KL as a carbonization agent.

Investigation of the Flammability and Thermal Stability of Halogen-Free Intumescent System in Biopolymer Composites Containing Biobased Carbonization Agent and Mechanism of Their Char Formation

Starch, being a polyhydric compound with its natural charring ability, is an ideal candidate to serve as a carbonization agent in an intumescent system. This charring ability of starch, if accompanied by an acidic source, can generate an effective intumescent flame retardant (IFR) system, but the performance of starch-based composites in an IFR system has not been tested in detail. Here, we describe a PLA-based IFR system consisting of ammonium polyphosphate (APP) as acidic source and cornstarch as carbon source. We prepared different formulations by melt compounding followed by molding into sheets by hot pressing. The thermal behavior and surface morphology of the composites was investigated by thermogravimetric analysis and scanning electron microscopy respectively. We also conducted limiting oxygen index (LOI), UL-94, and cone calorimetry tests to characterize the flame-retardant properties. Cone calorimetry revealed a 66% reduction in the peak heat release rate of the IFR composites compared to pure PLA and indicated the development of an intumescent structure by leaving a residual mass of 43% relative to the initial mass of the sample. A mechanism of char formation has also been discussed in detail.

Synthesis of DOPO-HQ-functionalized graphene oxide as a novel and efficient flame retardant and its application on polylactic acid: Thermal property, flame retardancy, and mechanical performance

The fabrication of biodegradable polymer nanocomposites with improved flame retardancy has been an urgent task in practical because of the huge benefits of biodegradable polymers. In this work, 10-(2,5-dihydroxyl phenyl)-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO-HQ)-functionalized graphene oxide (GO) (FGO-HQ) was used as a novel and highly efficient flame retardant (FR) to improve the flame retardancy of polylactide (PLA) nanocomposites. Contributed by the bi-phase flame retardant action, including the physical barrier char in solid phase and the decreased flammable volatiles in gas phase, the resultant PLA/FGO-HQ nanocomposites presented excellent flame resistance at the loading of 6 wt% FR: UL-94 reached V-0 rating; peak heat release rate (PHRR) and total heat release (THR) decreased by 24.0% and 43.0%, respectively; smoke production rate (SPR) and total smoke release (TSR) decreased by 46% and 83%, respectively. For further confirming its flame-resistance mechanism, thermogravimetric analysis/infrared spectrometry (TG-IR) and Fourier transform infrared spectra (FT-IR), scanning electron microscope (SEM), and Raman spectroscopy were employed. Results indicated that the incorporation of FGO-HQ can effectively reduce the evaporation of flammable gaseous product in gas phase through quenching free radicals. Meanwhile, graphitized carbons are formed in the residual char and PLA/FGO-HQ sample can achieve a good thermal stability in the combustion with phosphorus-containing compounds and aromatic structure in the solid phase. Furthermore, the tensile strength of PLA nanocomposites presented good mechanical properties with the addition of FR as well. These results suggested that the incorporation of FGO-HQ FR not only improve the flame retardancy and thermal stability of biodegradable polymer nanocomposites but also without sacrificing their mechanical properties.

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.

Development of one-step synthesized LDH reinforced multifunctional poly(amide–imide) matrix containing xanthene rings: study on thermal stability and flame retardancy

New exfoliated poly(amide–imide)/Zn–Al layered double hydroxide (LDH) nanocomposites were synthesized by solution intercalation using synthesized organo-modified LDH (OLDH) as nanofiller obtained by one-step method.

Flame retardant and anti-dripping properties of polylactic acid/poly(bis(phenoxy)phosphazene)/expandable graphite composite and its flame retardant mechanism

Poly(bis(phenoxy)phosphazene) combining with expandable graphite exhibit gaseous phase and condensed phase flame mechanism in PLA matrix.

A new approach to reducing the flammability of layered double hydroxide (LDH)-based polymer composites: preparation and characterization of dye structure-intercalated LDH and its effect on the flammability of polypropylene-grafted maleic anhydride/d-LDH composites

Dye structure-intercalated layered double hydroxide (d-LDH) was synthesized using a one-step method, and its intercalated behaviors have been characterized by Fourier transform infrared spectroscopy (FTIR), wide angle X-ray scattering (WAXS), scanning electron microscopy, thermogravimetric analysis (TGA), etc. As a novel functional potential fire-retarding nanofiller, it was used to prepare a polypropylene-grafted maleic anhydride (PP-g-MA)/d-LDH composite by refluxing the mixture of d-LDH and PP-g-MA in xylene, aiming to investigate its effect on the flammability of the PP-g-MA composite. The morphological properties, thermal stability, and flame retardant properties of the PP-g-MA/d-LDH composite were determined by FTIR, WAXS, transmission electron microscopy, TGA, and microscale combustion calorimetry. Compared with NO3-LDH (unmodified LDH) and LDH intercalated by sodium dodecylbenzenesulfonate (conventional organo-modified LDH), d-LDH can significantly decrease the heat release rate and the total heat release of the PP-g-MA composite, offering a new approach to imparting low flammability to LDH-based polymer composites.