Preparation and flame retardancy of an intumescent flame-retardant epoxy resin system constructed by multiple flame-retardant compositions containing phosphorus and nitrogen heterocycle

Synthesis of a Novel P/N-Triazine-Containing Ring Flame Retardant and Its Application in Epoxy Resin

To meet the environmental protection and flame retardancy requirements for epoxy resins (EPs) in certain fields, in this study, a novel triazine-ring-containing DOPO-derived compound (VDPD), derived from vanillin, 2,4-Diamino-6-phenyl-1,3,5-triazine, and 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO), was synthesized using a one-pot method. Flame-retardant epoxy resin (FREP) was prepared by adding various ratios of VDPD to EP and curing with 4,4-diaminodiphenylmethane (DDM). The curing behavior, thermal stability, mechanical properties, and flame-retardant properties of the FREP were examined in various tests. According to the results, when the amount of VDPD added to the EP increased, the glass transition temperature of the FREP decreased linearly, and the flame-retardant properties gradually improved. With a 0.4 wt.% P content, the vertical burning rating of EP/DDM/VDPD-0.4 (according to the theoretical content of VDPD) reached the V-0 level, and the LOI value reached 33.1%. In addition, the results of a CCT showed that the peak heat release rate (PHRR) of EP/DDM/VDPD-0.4 decreased by 32% in comparison with that of the EP. Furthermore, compared with those of the EP, the tensile strength of EP/DDM/VDPD-0.4 decreased from 80.2 MPa to 74.3 MPa, only decreasing by 6 MPa, and the tensile modulus increased. Overall, VDPD can maintain the mechanical properties of EP and effectively improve its flame-retardant properties.

A New Phosphorous/Nitrogen-Containing Flame-Retardant Film with High Adhesion for Jute Fiber Composites

In this work, a novel P/N flame-retardant monomer (PDHAA) was synthesized through reacting phenyl dichlorophosphate (PDCP) with N-hydroxyethyl acrylamide (HEAA). The structure of PDHAA was confirmed using Fourier transform infrared (FTIR) spectroscopy and proton nuclear magnetic resonance (NMR) spectroscopy. PDHAA monomer and 2-hydroxyethyl methacrylate phosphate (PM-2) monomer were mixed at different mass ratios, to prepare UV-curable coatings, and then applied to the surface of fiber needled felts (FNFs), to improve their flame retardancy. PM-2 was introduced to reduce the curing time of the flame-retardant coatings and improve the adhesion between the coating and the fiber needled felts (FNFs). The research results indicated that the surface flame-retardant FNFs had a high limiting oxygen index (LOI) and rapidly self-extinguished in a horizontal combustion test and passed a UL-94 V-0 test. At the same time, the CO and CO₂ emissions were greatly reduced, and the carbon residue rate was increased. In addition, the introduction of the coating improved the mechanical properties of the FNFs. Therefore, this simple and efficient UV-curable surface flame-retardant strategy has broad application prospects in the field of fire protection.

Fabrication of a bi-hydroxyl-bi-DOPO compound with excellent quenching and charring capacities for lignin-based epoxy resin

In this study, lignin-based epoxy resins (EP) were fabricated using lignin, phenol and glyoxal as crosslinking reagents. For improving the flame retardancy, a bi-DOPO compound with bi-hydroxyl structure was successfully synthesized, containing excellent quenching and charring capacities. Good pyrolysis behaviors of as-synthesized flame retardant resulted in significant quenching effect via structure decomposition to release PO and PO₂ free radicals for capturing reactive H and OH radicals produced from epoxy combustion. With addition of 0.18 wt% phosphorus, epoxy composite (10% LPG-ER-4) passed V-0 rating with high limited oxygen index (LOI) value of 35.2%. Cone calorimeter tests showed that heat release (including heat release rate (HRR) and total heat release (THR)) from combustion was reduced with assistance of flame retardant. Char residue analyses illustrated that bi-hydroxyl structure in DOPO-based flame retardant benefited the formation of char layer with higher compactness and integrity to serve as a protective shell of interior epoxy matrix. Furthermore, exterior pore size of char residue was narrowed or blocked to avoid the release of heat and volatiles generated from combustion. This study provided a feasible method to improve flame retardancy of lignin-based EP and proposed flame-retardant mechanism both in gaseous and solid phases.

Transparent low-flammability epoxy resins using a benzoguanamine-based DOPO derivative

We successfully prepared a highly effective flame-retardant additive called hsalbenzoguanamine phosphaphenanthrene (HDPD) through salicylaldehyde and nitrogen-rich benzoguanamine. The introduction of HDPD into epoxy resin (EP) sharply enhanced the flame retardancy of EP/HDPD thermosets. The introduction of 6 wt% HDPD into EP succeeded in reaching the V-0 rating. Limited oxygen index results revealed the high flame-retarding performance of HDPD. Cone calorimeter test data revealed that heat and smoke released from EP/6 wt% HDPD thermoset were significantly restrained. In addition, EP/6 wt% HDPD thermoset demonstrated excellent transmittance and mechanical strength. The transmittance of EP/6 wt% HDPD was assessed from 520 to 800 nm. The results showed that transmittance of EP/6 wt% HDPD were nearly 90% of the control group.

A transparent and intumescent phosphaphenanthrene/phenylpyrazole-containing epoxy resin system and its flame retardancy

A novel intumescent flame retardant, PPMD, was designed from phosphaphenanthrene and nitrogen heterocycles through the two-step gut reactions of 1,4-phthalaldehyde and 3-methyl-1-phe-nylpyrazol-5-ylamine. After determination of its structure by nuclear magnetic resonance and Fourier-transform infrared analyses, PPMD was added to an epoxy resin (EP) to facilitate a curing process. Thus, EP/PPMD samples with excellent transparency and flame retardancy were acquired. For example, the EP sample satisfied the UL-94 V-0 standard and achieved a limiting oxygen index value of 30.5% because of the incorporation of 5 wt% PPMD. The cone calorimeter test of the EP/5% PPMD sample revealed that its total smoke production (TSP) and total heat release (THR) values of EP/5% PPMD was only 22.5% and 56.4% of the control group, respectively. Moreover, the average effective heat of combustion (av-EHC) value of EP/5% PPMD was reduced by 34.1%, indicating that PPMD possessed high flame-inhibition activity and smoke suppression efficiency. The flame-retardant mechanisms of PPMD were also investigated in gas phase by pyrolysis-gas chromatography/mass spectrometry (Py-GC/MS) and in condensed phase by XPS and IR.

Preparation and characterization of polydopamine/melamine microencapsulated red phosphorus and its flame retardance in epoxy resin

Polydopamine/melamine composite microencapsulated red phosphorus (RP@PDA/MA) was prepared and applied as the flame retardant for epoxy resin (EP) in this work. For comparison, polydopamine (PDA) coated red phosphorus (RP@PDA) was also prepared. The microstructure, chemical composition and thermal decomposition of the as prepared samples were systematically characterized. The results showed that PDA and PDA/MA shell structures were fabricated successfully via convenient water-based processes at room temperature. The flame retardance of red phosphorus (RP), RP@PDA, and RP@PDA/MA on EP was evaluated. The results showed that EP blending with 7 wt% RP@PDA/MA passed V-0 degree in the vertical burning test (UL-94), reached a limited oxygen index (LOI) of 30.9% and decreased the peak heat release rate of EP by 65.1% in the cone calorimeter test. The satisfactory flame retardance can be attributed to the intumescent flame retardant system consisting of RP@PDA/MA. The PDA and PDA/MA shell structures also improved the compatibility between RP and EP, thus RP@PDA and RP@PDA/MA had less significant impact on the tensile-strain properties of EP.

Synthesis of chitosan-based flame retardant and its fire resistance in epoxy resin

A novel flame retardant CCD was synthesized by the condensation between cinnamalde and chitosan, followed by the addition reaction with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide(DOPO), and CCD was named from the initials of the three raw materials. The intermediate product CC and the target product CCD was then characterized by infrared spectrometry and elemental analysis. The flame retardancy of EP thermosets modified by CCD was dramatically improved. Epoxy resin (EP) with 10wt% CCD passed vertical burning (UL-94) V-0 rating and possessed limited oxygen index (LOI) value of 31.6 %. Cone calorimeter test exhibited the introduction of 3.5g CCD into 35g EP decreased the total heat release by 38.8 % and decreased the total smoke product by 72.0 %. XPS, FTIR, SEM and Raman tests were proceeded to determine the char residue for EP/10 % CCD thermoset, and the results showed that char residue for EP/10 % CCD thermoset possessed dense and compact structure which played a positive effect in blocking the exchange of heat and gas.

Recent Developments in the Flame-Retardant System of Epoxy Resin

With the increasing emphasis on environmental protection, the development of flame retardants for epoxy resin (EP) has tended to be non-toxic, efficient, multifunctional and systematic. Currently reported flame retardants have been capable of providing flame retardancy, heat resistance and thermal stability to EP. However, many aspects still need to be further improved. This paper reviews the development of EPs in halogen-free flame retardants, focusing on phosphorus flame retardants, carbon-based materials, silicon flame retardants, inorganic nanofillers, and metal-containing compounds. These flame retardants can be used on their own or in combination to achieve the desired results. The effects of these flame retardants on the thermal stability and flame retardancy of EPs were discussed. Despite the great progress on flame retardants for EP in recent years, further improvement of EP is needed to obtain numerous eco-friendly high-performance materials.

Preparation and Characterization of Flame-Retarded Poly(butylene terephthalate)/Poly(ethylene terephthalate) Blends: Effect of Content and Type of Flame Retardant

A flame retardant named TAD was synthesized by the reaction of 9,10-Dihydro-9-oxa-10-phosphaphenanthrene-10-oxide and triallyl isocyanurate at first. Then, novel flameretarded materials based on PBT and PET resin were formulated via melt blending with TAD, expandable graphite (EG), and a mixture of both. The effect of flame retardant type and TAD content on the flame behavior of PBT/PET blend was carefully investigated. TAD contributed towards higher LOI value and better UL-94 performance than EG. However, the best V-0 rating in the UL-94 test was achieved by the incorporation of TAD/EG mixture into the resin matrix. TAD/EG combination exhibited clear synergistic effect on both reducing the flaming intensity and increasing the residual char layer, as confirmed by cone calorimeter tests and TGA results. SEM images combined with XPS analysis revealed that expansion and migration of EG locked the P-containing radicals from decomposing TAD into the condensed phase, which led to the formation of compact and continuous char layers. All the results in our studies demonstrate that incorporation of TAD with a charring agent EG is an effective and promising technique to develop flame-retarded PBT/PET material, which has high potential for applications in the areas of electronic devices, household products, and automotive parts.

A biobased Schiff base from protocatechualdehyde and its application in flame-retardant, low-smoke epoxy resin systems

Herein, a new renewable Schiff base flame retardant 4,4'-((1E,1'E)-((oxybis(4,1-phenylene))bis(azanylylidene))bis(methanylylidene))bis(benzene-1,2-diol) (PH-ODA) was prepared by the reaction of protocatechualdehyde with 4,4'-diaminodiphenyl ether (ODA). PH-ODA (acting as a carbonization agent) combined with ammonium polyphosphate (APP) were used as intumescent flame retardants for commercial bisphenol A epoxy resin (DGEBA). For the cured epoxy resin containing 7.5% APP and 2.5% PH-ODA, the limiting oxygen index (LOI) reached 29.9% (with the V-0 rating in UL-94 test), and the peak heat release rate and total smoke production were respectively decreased by 88.1% and 68.3%, compared with pure epoxy resin. The enhancement of fire-safety performance was due to PH-ODA/APP promoting the formation of a compact intumescent char structure. It was also found that the synergism between PH-ODA and APP was helpful to enhance the fire resistance of the epoxy matrix. This work provides a facile and sustainable route for synthesizing Schiff base compounds from biomass-derived resources, possessing great potential for application in highly-effective intumescent flame retardants.

Bi2Se3 decorated recyclable liquid-exfoliated MoS2 nanosheets: Towards suppress smoke emission and improve mechanical properties of epoxy resin

Bimetallic compounds have been proved superior suppression effect on smoke emission during combustion of polymers. In this work, MoS₂/Bi₂Se₃ (MB) hybrids were prepared by a facile wet chemical method and showed superior performance on smoke suppression of EP matrix during combustion. N-vinyl pyrrolidone (NVP) was employed to exfoliate molybdenum disulfide (MoS₂) nanosheets in a recyclable method, which showed high efficiency and was recyclable. Exfoliated MoS₂ exhibited large surface area and used as carriers to synthesize MB hybrids. Considering the catalytic effect of bismuth and molybdenum, the hybrids had a great influence on the smoke emission behaviors of EP composites. The smoke production was obviously suppressed during the flaming combustion (more than 22% and 23% decrease obtained from cone calorimeter and steady state tube furnace, respectively) or smolder processes (more than 23% decrease obtained from smoke chamber) at only 1 wt% content of MB hybrids. What's more, due to superior dispersion state, the addition of MB hybrids also enhanced the mechanical properties of EP matrix, including wear resistance and tensile property. This work provided a safe and green exfoliation method of MoS₂ to prepare polymers/MoS₂ composites and also constructed a novel binary hybrids for enhancing combination performances of polymers.

Phosphorus-Based α-Amino Acid Mimetic for Enhanced Flame-Retardant Properties in an Epoxy Resin

This work demonstrates the introduction of a phosphonate moiety into a commonly used curing agent, 4,4′-diaminodiphenylmethane (DDM), via an α-aminophosphonate. This compound (DDMP) can be prepared and isolated in analytical purity in under 1h and in good yield (71%). Thermoset polymer (epoxy-derived) samples were prepared using a room-temperature standard cure (SC) and a post-cured (PC) protocol to encourage incorporation of the α-aminophosphonate into the polymer network, with improved flammability properties observed for the latter. Thermogravimetric analysis under a nitrogen atmosphere showed increased char yield at 600°C, and similar observations were made when analysis was conducted in air. Significant reductions in flammability are observed at very low phosphorus content (P%=0.16–0.49%), demonstrated by higher char yields (25.5 from 14.0% in air), decreased burn time from ignition (60 to 24s), and decreased mass loss after ignition (87.6 to 58.5%). Limiting Oxygen Index for the neat polymer (P%=0%, 20.3±0.8%) increased with increasing α-aminophosphonate additive (P%=0.16%, 20.8±0.6%; P%=0.32%, 21.4±0.4%; P%=0.49%, 22.6±0.8%).

Preparation and performance testing of superhydrophobic flame retardant cotton fabric

A superhydrophobic flame retardant coating was fabricated using a simple method of depositing a DAP coating and a H-ZrO₂@PDMS coating on the surface of a cotton fabric. Thermal stability tests and vertical burning tests demonstrate the excellent flame retardancy of the coating.