Fabrication and origin of new flame retarding bismaleimide resin system with low dielectric constant and loss based on microencapsulated hexaphenoxycyclotriphosphazene in low phosphorus content

Synergistic effect of modified anhydrous magnesium carbonate and hexaphenoxycyclotriphosphazene on flame retardancy of ethylene-vinyl acetate copolymer

Ethylene-vinyl acetate copolymer (EVA) is widely used in various applications; however, its flammability limits its application in wire and cable industries. In this study, 3-methacryloxypropyltrimethoxysilane (KH570) was successfully grafted onto the surface of anhydrous magnesium carbonate (AMC) by alkali activation treatment. The KH570 modified AMC (AMC@KH570) was then introduced into the EVA matrix along with hexaphenoxycyclotriphosphazene (HPCTP) to assess their effects on the flame retardancy and mechanical properties of EVA composites. The results illustrate a significant synergistic effect in enhancing the flame retardancy of EVA composites by using AMC@KH570 and HPCTP, and the limiting oxygen index (LOI) and vertical burning test (UL-94) of EVA filled with 5 wt% HPCTP and 45 wt% AMC@KH570 (mAMC/H-45-5) reached 27.6% and V-0, respectively. The flame retardant mechanism was investigated by thermogravimetric/infrared (TG-IR) spectroscopy and residual carbon composition analysis. The results show that the thermal decomposition of AMC@KH570 and HPCTP consists of gas dilution, free radical quenching, and catalytic carbonization. Furthermore, KH570 works as a bridge to improve the compatibility of AMC and EVA matrix, which offsets the mechanical loss of EVA to some extent. The present research provides a new path to modify AMC and fabricate EVA composites with excellent flame retardant properties.

The Flame Retardant and Mechanical Properties of the Epoxy Modified by an Efficient DOPO-Based Flame Retardant

Currently, the mechanical performance reduction caused by excessive phosphorus content in the halogen-free flame-retardant EP has been an obstacle to its extensive application. This study presents the effective synthesis of a novel flame-retardant BDD with great efficiency, achieving an optimum phosphorus level of merely 0.25 wt %. The structure of BDD was verified by FTIR, 1H NMR, 31P NMR and XPS spectra. To investigate the flame-retardant properties of BDD, several EPs with various phosphorus levels were synthesized. The addition of phosphorus to the EP significantly increases its LOI value from 25.8% to 33.4% at a phosphorus level of 0.25 wt%. Additionally, the resin achieves a V-0 grade in the UL 94 test. The P-HRR and THR of the modified resin measured by the cone calorimeter are also significantly reduced. At the same time, the addition of a modest quantity of BDD has a minimal impact on the mechanical properties of epoxy resin. This study shows that the removal of hydroxyl groups significantly enhances the fire resistance of phosphate-based flame retardants, thereby providing a novel approach to synthesizing efficient flame retardants.

Enhanced Thermal Conductivity of Epoxy Composites Filled with Al2O3/Boron Nitride Hybrids for Underfill Encapsulation Materials

In this study, a thermal conductivity of 0.22 W·m-1·K-1 was obtained for pristine epoxy (EP), and the impact of a hybrid filler composed of two-dimensional (2D) flake-like boron nitride (BN) and zero-dimensional (0D) spherical micro-sized aluminum oxide (Al2O3) on the thermal conductivity of epoxy resin was investigated. With 80 wt.% hybrid Al2O3-BN filler contents, the thermal conductivity of the EP composite reached 1.72 W·m-1·K-1, increasing approximately 7.8-fold with respect to the pure epoxy matrix. Furthermore, different important properties for the application were analyzed, such as Fourier-transform infrared (FTIR) spectra, viscosity, morphology, coefficient of thermal expansion (CTE), glass transition temperature (Tg), decomposition temperature (Td), dielectric properties, and thermal infrared images. The obtained thermal performance is suitable for specific electronic applications such as flip-chip underfill packaging.

Effects of α-zirconium phosphate and zirconium organophosphonate on the thermal, mechanical and flame retardant properties of intumescent flame retardant high density polyethylene composites

The combination of synergistic agents with intumescent flame retardants (IFRs) is an excellent strategy for the development of high-performance flame retardant composites. Zirconium-based compounds are multifunctional materials with applications in various fields. In this study, zirconium-based compounds were synthesized and then combined with an IFR composed of ammonium polyphosphate (APP) and tris (2-hydroxyethyl) isocyanurate (THEIC) to prepare flame retardant high density polyethylene (HDPE) composites. α-Zirconium phosphate (α-ZrP) and two organic–inorganic hybrids (zirconium organophosphonate), Zr-ATMP and Zr-PA, were prepared using amino tri (methylene phosphonic acid) (ATMP) and phytic acid (PA), respectively, and their thermal, mechanical and flame retardant properties were characterized by thermogravimetric analysis, tensile test, limiting oxygen index (LOI) measurement and cone calorimetry test. The results showed that the LOI value of HD/IFR/Zr-ATMP composite reached a maximum of 26.2% using 25 wt% of flame retardant containing 3 wt% of Zr-ATMP. Of the three zirconium-based compounds, Zr-ATMP and α-ZrP can reduce the peak heat release rate compared with the composite containing only IFR. However, zirconium-based compounds showed no significant improvement of tensile strength.

Zirconium-based compounds are combined with intumescent flame retardant (IFR) to prepare flame retardant high density polyethylene composites.

Improved thermal properties of epoxy resin modified with polymethyl methacrylate-microencapsulated phosphorus-nitrogen-containing flame retardant

Epoxy resin (EP) composites with improved thermal resistance were fabricated. To solve the problem of low thermal resistance derived from phosphazene flame-retardant additives, we designed a system based on flame-retardant microcapsules P(H), with hexaphenoxycyclotriphosphazene as the core and polymethyl methacrylate as the shell. The core–shell structure was characterized and confirmed. The thermal resistance of the cured EP composites containing 1 wt% P(H) microcapsules was improved because of the increased glass transition temperatures. The P(2.75H)/EP composites can reach a limited oxygen index of 30.5% and V-1 rating in UL-94 tests. Heat and gas release rates were reduced during combustion tests. Residual images implied that the P(H) microcapsules may promote the formation of a flame-retardant char layer. Pyrolysis analysis demonstrated that the P(H) microcapsules can decompose in two procedures to produce flame-retardant gas components. Therefore, the flame-retardant mechanism involved the flame inhibition effect in the gas phase, and the charring effect in the condensed phase.

Epoxy resin composites with improved thermal resistance and flame retardancy were fabricated based on P(H) microcapsules.

Thermally stabilized bismaleimide–triazine resin composites for 10-GHz level high-frequency application

A hybrid cured resin with excellent dielectric and thermal properties was prepared with bismaleimide–triazine (BT) resin modified with 2,2′-diallylbisphenol A (DBA). The thermal and dielectric properties of the resin were investigated, and the effect of DBA concentration on the curing reaction was determined. Results indicated that DBA significantly influenced the curing reaction and the properties of the cured product. The modified BT resins exhibited outstanding thermal stability (initial decomposition temperature was over 400°C), although the stability was slightly lower than that of pure BT resins. The dielectric constant and dielectric loss of the cured resin decreased when DBA was introduced into the BT resins. Moreover, the fabricated resins showed dielectric constant of 2.91–3.07 and dielectric loss lower than 0.0057 under the testing high-frequency range of 1 GHz to 15 GHz. Overall, the BT resins modified by DBA display great potential to be applied in high frequency field.