Highly efficient flame-retardant glass-fiber-reinforced polyamide 6T system based on a novel DOPO-based derivative: Flame retardancy, thermal decomposition, and pyrolysis behavior

Synergistic Effects of 9,10-Dihydro-9-oxa-10-phosphaphenanthrene-10-oxide-Based Derivative and Modified Sepiolite on Flame-Retarded Poly (Ethylene Oxide)-Poly (Butylene Adipate-Co-Terephthalate) Composites

A 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO)-based derivative (PN-DOPO) combined with aluminium phosphates-coated sepiolite (Sep@AlPO4) was used to improve the flame retardance, thermal stability and mechanical performances of poly (ethylene oxide) (PEO)/poly (butylene adipate-co-terephthalate) (PBAT) blends. The synergistic effects of PN-DOPO and Sep@AlPO4 on flame-retarded PEO/PBAT composites were systematically discussed. Results indicated that introducing 5 wt% Sep@AlPO4 with 10 wt% PN-DOPO into PEO/PBAT achieved a V-1 rating for the UL-94 test and increased the limiting oxygen index value to 23.7%. Moreover, the peak heat release rate (p-HRR), average HRR and total heat release values of PEO/PBAT/PN10%/Sep5% composites decreased by 35.6%, 11.0% and 23.0% compared with those of PEO/PBAT, respectively. Thermogravimetric analysis (TGA) results confirmed that PN-DOPO/Sep@AlPO4 enhanced the initial thermal stability and char yield of PEO/PBAT matrix, and TGA/Fourier transform infrared spectrometry results revealed that the composites exhibited the characteristic absorption peaks of phosphorous-containing groups and an increase in gas-phase volatiles during thermal degradation. The morphological structures of the residues indicated that PN-DOPO and Sep@AlPO4 mixtures produced a more dense and continuous char layer on the composite surface during burning. Rheological behaviour revealed that higher complex viscosity and modulus values of PEO/PBAT/PN-DOPO/Sep@AlPO4 sample could also promote the crosslinking network structure of condensed phases during combustion. Furthermore, the PEO/PBAT/PN-DOPO/Sep@AlPO4 composites exhibited superior elongation at break and flexural performance than the PEO/PBAT system. All results demonstrated that the PEO/PBAT system modified with PN-DOPO/Sep@AlPO4 showed remarkable flame retardance, and improved thermal stability and mechanical properties, indicating its potential application in areas requiring fire safety.

Analyzing Temperature Distribution Patterns on the Facing and Backside Surface: Investigating Combustion Performance of Flame-Retardant Particle Boards Using Aluminum Hypophosphite, Intumescent, and Magnesium Hydroxide Flame Retardants

Particle boards are manufactured through a hot pressing process using wood materials (natural polymer materials) and adhesive, which find common usage in indoor decorative finishing materials. Flame-retardant particleboard, crucial for fire safety in such applications, undergoes performance analysis that includes assessing temperature distribution across its facing surface and temperature increase on the backside surface during facade combustion, yielding critical insights into fire scenario development. In this study, a compact flame spread apparatus is utilized to examine the flame retardancy and combustion behavior of particle boards, with a specific emphasis on the application of cost-effective flame retardants, encompassing aluminum hypophosphite (ALHP), an intumescent flame retardant (IFR) comprising ammonium polyphosphate (APP), melamine (MEL), and Dipentaerythritol (DPE), alongside magnesium hydroxide (MDH), and their associated combustion characteristics. The D300°C values, representing the vertical distance from the ignition point (IP) to P300°C (the temperature point at 300 °C farthest from IP), are measured using a compact temperature distribution measurement platform. For MDH/PB, APP + MEL + DPE/PB, and ALHP/PB samples, the respective D300°C values of 145.79 mm, 117.81 mm, and 118.57 mm indicate reductions of 11.11%, 28.17%, and 27.71%, compared to the untreated sample's value of 164.02 mm. The particle boards treated with ALHP, IFR, and MDH demonstrated distinct flame-retardant mechanisms. MDH/PB relied on the thermal decomposition of MDH to produce MgO and H2O for flame retardancy, while APP + MEL + DPE/PB achieved flame retardancy through a cross-linked structure with char expansion, polyphosphate, and pyrophosphate during combustion. On the other hand, ALHP/PB attained flame retardancy by reacting with wood materials and adhesives, forming a stable condensed P-N-C structure. This study serves as a performance reference for the production of cost-effective flame-resistant particleboards and offers a practical method for assessing its fire-resistant properties when used as a decorative finishing material on facades in real fire situations.

Study of the Self-Polymerization of Epoxy/Phthalonitrile Copolymers and Their High-Performance Fiber-Reinforced Laminates

Self-polymerization epoxy/phthalonitrile (APPEN) pre-polymers were studied systematically, and then, gelation time and differential scanning calorimetry (DSC) were employed to investigate their curing behaviors. Taking advantage of orthogonal test analysis, the key factors that affected the co-polymerization of APPEN were defined and the appropriate pre-polymerization conditions were analyzed. A possible curing mechanism of APPEN was proposed. Then, the thermomechanical and mechanical properties of glass-fiber-reinforced APPEN laminates (APPEN/GF) prepared at 180 °C were analyzed to understand the cross-linked and aggregation structures. Fracture surface of the composite laminates was also investigated to reveal the copolymerization degree and the interfacial binding. The results indicated that APPEN/GF composites exhibit outstanding mechanical and thermomechanical properties (flexural strength, 712 MPa, flexural modulus, 38 GPa, and Tg > 185 °C). The thermal stability (T5% > 334 °C and IPDT reached 1482 °C) of APPEN/GF composites was also investigated to further reveal the copolymerization between epoxy resin and aminophthalonitrile, which may be beneficial to the application of epoxy-matrix-based composites in the field of high-performance polymer composites.

Thermal degradation and flame retardancy of nylon 6/aluminum methylmethoxy phosphonate composites

An aluminum methylmethoxyphosphonate (AlPo)-based flame retardant (FR) was synthesized. Thermal degradation and flame retardancy of nylon 6 (PA6)/AlPo composites were examined and compared with PA6/commercial aluminum diethylphosphinate (AlPi) composites. The PA6/AlPo composite achieved a V-0 rating at 20 wt% loading during the UL-94 test, and it exhibited the formation of a charred layer that protected the polymer from burning and reduced the release of gases during the combustion of PA6. AlPo demonstrated exceptional performance in gaseous and condensed phases in the PA6 matrix, whereas AlPi only worked in the gaseous phase. The differences between the thermal degradation mechanisms and flame retardancies of AlPi and AlPo were investigated via Fourier-transform infrared (FT-IR) spectroscopy, thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and cone calorimetry. A suitable degradation mechanism was proposed to aid the development of flame retardants in the future.

Thermal degradation behavior and flame retardant properties of PET/DiDOPO conjugated flame retardant composites*

PET/DIDOPO conjugated flame retardant composites were prepared by melt blending of styrene bridged DOPO (DIDOPO) into polyethylene terephthalate (PET). The flame retardancy, rheological behavior, and thermal degradation behavior of the composite were characterized by vertical combustion test (UL-94), limit oxygen index test (LOI), rotational rheometer, and thermogravimetry (TG). The results showed that the flame retardant composite with V-0 grade was obtained when the amount of DIDOPO is 12.5wt%, and the corresponding LOI value was 56.87% higher than that of PET. The thermogravimetry-fourier infrared spectroscopy (TG-FTIR) test results showed that DIDOPO could promote the degradation of PET/DIDOPO materials, and release phosphorus-containing free radicals to quench the flame, therefore slowing down the combustion process, and mainly playing the key flame retardant role in gas-phase.

Terminal group effects of DOPO-conjugated flame retardant on polyamide 6: Thermal stability, flame retardancy and mechanical performances

Two DOPO-conjugated flame retardants with or without amino terminal groups (DOPO-NH₂ and DIDOPO, respectively) were synthesized and incorporated into polyamide 6 (PA6). Results demonstrated the DOPO-NH₂ endowed superior thermal, flame retardant and mechanical performances to PA6 composites. With the same loading of 15 wt%, DOPO-NH₂ can catalyze the PA6 matrix more effectively and result in more residues at high temperature. The PA6 composites containing DOPO-NH₂ exhibited higher LOI (28.0%) compared to 25.0% for the sample containing DIDOPO, and the lower heat release capacity and peak heat release rate. Furthermore, the overall mechanical properties of PA6 composites containing DOPO-NH₂ outperformed the samples containing DIDOPO, even superior to that for PA6. Such a significant difference can be mainly attributed to the existence of amino-terminal group, which can interact with carboxyl group in PA6 as confirmed by dynamic mechanical analysis, improving the compatibility between the flame retardant and PA6 matrix.

Mode of Action of Zn-DOPOx and Melamine Polyphosphate as Flame Retardants in Glass Fiber-Reinforced Polyamide 66

In this study, the flame retardant effect of the Zn salt of 10-hydroxy-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (Zn-DOPOx), melamine polyphosphate (MPP) and their mixture was investigated towards the mode of action in glass fiber-reinforced polyamide 66 (PA 66 GF). The flammability was evaluated using UL 94 V and cone calorimetry. Influence on char formation was analyzed by SEM. Thermal decomposition of Zn-DOPOx and MPP was studied by TGA and ATR-FTIR. The release of gaseous PA 66 decomposition products was investigated using TGA-DTA-FTIR. Combining Zn-DOPOx and MPP leads to an improvement in flame retardancy, most pronounced for equal parts of weight. Mode of action changes significantly for Zn-DOPOx:MPP (1:1) compared to the sole components and a strong interaction between Zn-DOPOx and MPP is revealed, resulting in a more open char structure. Fuel dilution as well as less exothermic decomposition are essential for the mode of action of the combination. Through low HRR values and high CO/CO₂ ratio during cone calorimetry measurements, a significant increase in gas phase activity was proven. Therefore, it is concluded that Zn-DOPOx:MPP (1:1) leads to a significant increase in flame retardancy through a combination of mode of actions in the gas and condensed phase resulting from the change in thermal stability.

Synergistic Effects of DOPO-Based Derivative and Organo-Montmorillonite on Flame Retardancy, Thermal Stability and Mechanical Properties of Polypropylene

Polypropylene (PP), as a general thermoplastic polymer, is broadly used in different fields. However, the high flammability, melt dripping and poor mechanical properties of PP are a constraint to the expansion of its applications. In this paper, PP composites containing a combination of a phenethyl-bridged DOPO derivative (PN-DOPO) and organic montmorillonite (OMMT) were prepared via melt blending. The synergistic effects of PN-DOPO and OMMT on the flame retardancy, thermal stability and mechanical properties of PP composites were investigated systematically. The results showed that 20 wt% addition of PN-DOPO with OMMT improved the flame retardancy of PP composites. In particular, the introduction of 17 wt% PN-DOPO and 3 wt% OMMT increased the LOI values of the PP matrix from 17.2% to 23.6%, and the sample reached the V-0 level and reduced the heat release rate and total heat release. TGA indicated that OMMT could improve the thermal stability of the PP/PN-DOPO blends and promote the char residues of PP systems. Rheological behaviour showed a higher storage modulus, loss modulus and complex viscosity of PP/PN-DOPO/OMMT composites, suggesting a more effective network structure. In addition, the tensile strength, flexural properties and impact strength of the PP/PN-DOPO/OMMT composites actually increased for a good dispersion effect. Combined with the char layer analysis, the introduction of OMMT promoted more continuous and compact structural layers containing an aluminium-silicon barrier and phosphorus-containing carbonaceous char in the condensed phase. OMMT can improve the flame retardancy, thermal stability and mechanical properties of PP, and, thus, PN-DOPO/OMMT blends can serve as an efficient synergistic system for flame-retarded PP composites.

A cross-linked charring strategy for mitigating the hazards of smoke and heat of aluminum diethylphosphonate/polyamide 6 by caged octaphenyl polyhedral oligomeric silsesquioxanes

Aluminum diethylphosphonate (ADP) is a highly efficient phosphorus-based flame retardant, widely used in polyamide 6 (PA6). However, ADP/PA6 releases large amounts of heat and smoke under high heat flux, which commonly means serious hazards to life and property. Octaphenyl polyhedral oligomeric silsesquioxanes (OPS) is an organic-inorganic hybrid silicon compound, playing flame retardant role in condensed phase. In this work, combustion behaviors of OPS/ADP/PA6 were investigated by limited oxygen index (LOI), UL94 and cone calorimeter (CONE) tests. The LOI and UL94 rating results did not change obviously, while the CONE data and smoke density data showed the synergistic effect of OPS and ADP in PA6. For 2.5%OPS/7.5%ADP/PA6, the peak values of heat, smoke and CO release rate (pk-HRR, pk-RSR, D_s, max with/without pilot flame and pk-COP) decreased by 60.2%, 82.1%, 45.9%/38.3% and 80.4% respectively, compared with 10%ADP/PA6. Moreover, 2.5%OPS/7.5%ADP/PA6 produced 337.5% more residue than 10%ADP/PA6. TGA, TG-IR, SEM-EDS, XPS and py-GC/MS were used to further explore the synergistic mechanism of OPS and ADP. It was verified that the cross-linked charring strategy apparently has weakened the hazards of smoke and heat of PA6. This work proposed a possible technical approach to solve both fire risk and heat/smoke hazards of PA6.

Flame Retardancy Behaviors of Flexible Polyurethane Foam Based on Reactive Dihydroxy P-N-containing Flame Retardants

Green and environment-friendly high-efficiency flame retardants (FRs) are crucial to polymer FR modification. Here, a green FR 2-((bis(2-hydroxyethyl)amino)methyl)-5,5-dimethyl-1,3,2-dioxaphosphinane 2-oxide (HAMPP) was synthesized. The HAMPP was incorporated with a cyclic phosphorus structure, which will readily carbonize to inhibit or prevent further combustion. Moreover, the HAMPP contains dihydroxy reactive groups that can be used as a monomer in the polymerization reaction to obtain the main chain containing phosphorus polymer. Research studies on FRs were based on flexible polyurethane foam (PU-HAMPPs). The limiting oxygen index value of PU foam with 10% HAMPP could reach 23.7%, passing a UL-94 V-0 rating together. With the addition of HAMPP, the peak heat release rate of PU foam decreased significantly, the decomposition temperature increased, the heat release capacity reduced by 31%, and the char yield increased by 42%. The chemical composition and morphology of the char residual have been studied and analyzed thoroughly. We find that HAMPP forms a molten viscous protective layer uniformly on the material surface and releases some incombustible gases. These indicated that the FR exploited both condensed-phase and gas-phase flame retardancy mechanisms. Besides, the addition of FRs improved the mechanical properties.

Synergistic Effects of Ladder and Cage Structured Phosphorus-Containing POSS with Tetrabutyl Titanate on Flame Retardancy of Vinyl Epoxy Resins

The cage and ladder structured phosphorus-containing polyhedral oligomeric silsesquioxanes (DOPO-POSS) have been synthesized through the hydrolytic condensation of 9,10-dihydro-9-oxa-10-phosphenanthrene-10-oxide (DOPO)-vinyl triethoxysilane (VTES). The unique ladder and cage–ladder structured components in DOPO-POSS endowed it with good solubility in vinyl epoxy resin (VE), and it was used with tetrabutyl titanate (TBT) to construct a phosphorus-silicon-titanium synergy system for the flame retardation of VE. Thermal stabilities, mechanical properties, and flame retardancy of the resultant VE composites were investigated by thermal gravimetric analysis (TGA), dynamic mechanical analysis (DMA), three-point bending tests, limiting oxygen index (LOI) measurement, and cone calorimetry. The experimental results showed that with the addition of only 4 wt% DOPO-POSS and 0.5 wt% TBT, the limiting oxygen index value (LOI) increased from 19.5 of pure VE to 24.2. With the addition of DOPO-POSS and TBT, the peak heat release rate (PHRR), total heat release (THR), smoke production rate (SPR), and total smoke production (TSP) were decreased significantly compared to VE-0. In addition, the VE composites showed improved thermal stabilities and mechanical properties comparable to that of the VE-0. The investigations on pyrolysis volatiles of cured VE further revealed that DOPO-POSS and TBT exerted flame retardant effects in gas phase. The results of char residue of the VE composites by SEM and XPS showed that TBT and DOPO-POSS can accelerate the char formation during the combustion, forming an interior char layer with the honeycomb cavity structure and dense exterior char layer, making the char strong with the formation of Si-O-Ti and Ti-O-P structures.

Cross-Linking Modification of Ammonium Polyphosphate via Ionic Exchange and Self-Assembly for Enhancing the Fire Safety Properties of Polypropylene

Modified ammonium polyphosphate (MAPP) was prepared as a novel mono-component intumescent flame retardant (IFR) via the ionic exchange between ammonium polyphosphate (APP) and piperazine sulfonate, which is synthesized by self-assembly using 1-(2-aminoethyl) piperazine (AEP) and p-aminobenzene sulfonic acid (ASC) as raw materials. This all-in-one IFR integrating three functional elements (carbon, acid, and gas source) showed more efficient flame retardancy and excellent smoke suppression as well as better mechanical properties than the conventional APP. The incorporation of 22.5 wt.% MAPP into polypropylene (PP) eliminated the melt dripping phenomenon and passed the UL-94 V-0 rating. The results of the cone calorimetry test (CCT) revealed that the release of heat, smoke, and CO is significantly decreased, demonstrating that this novel IFR endows PP with excellent fire safety more effectively. For PP/MAPP composites, a possible IFR mechanism was proposed based on the analysis of the pyrolysis gas and char residues.

Chain Extension and Synergistic Flame-Retardant Effect of Aromatic Schiff Base Diepoxide on Polyamide 6/Aluminum Diethylphosphinate Composites

A way to suppress the deterioration in mechanical properties of polyamide 6 (PA6) is required, especially with high loading of flame retardants in the matrix. In this study, a novel aromatic Schiff base diepoxide (DES) was synthesized. It exhibited an efficient chain extension effect on PA6 and a synergistic flame-retardant effect with aluminum diethylphosphinate (AlPi) for PA6. The PA6 composite with 16 wt.% AlPi only passed UL-94 V-0 rating at 1.6 mm thickness, while the combination of 1.5 wt.% DES with 13 wt.% AlPi induced PA6 to achieve a UL-94 V-0 rating at 0.8 mm thickness. The tensile, flexural, and Izod notched impact strengths were increased by 16.2%, 16.5%, and 24.9%, respectively, compared with those of V-0 flame-retarded PA6 composites with 16 wt.% AlPi. The flame-retarded mechanism of PA6/AlPi/DES was investigated by cone calorimetry and infrared characterization of the char residues and pyrolysis products. These results showed that DES had a synergistic effect with AlPi in condensed-phase flame retardation by promoting the production of aluminum phosphorus oxides and polyphosphates in the char residues.

Valorization of Industrial Lignin as Biobased Carbon Source in Fire Retardant System for Polyamide 11 Blends

In this study, two different types of industrial lignin (i.e., lignosulphonate lignin (LL) and kraft lignin (DL)) were exploited as charring agents with phosphorus-based flame retardants for polyamide 11 (PA11). The effect of lignins on the thermal stability and fire behavior of PA11 combined with phosphinate additives (namely, aluminum phosphinate (AlP) and zinc phosphinate (ZnP)) has been studied by thermogravimetric analysis (TGA), UL 94 vertical flame spread, and cone calorimetry tests. Various blends of flame retarded PA11 were prepared by melt process using a twin-screw extruder. Thermogravimetric analyses showed that the LL containing ternary blends are able to provide higher thermal stability, as well as a developed char residue. The decomposition of the phosphinates led to the formation of phosphate compounds in the condensed phase, which promotes the formation of a stable char. Flammability tests showed that LL/ZnP ternary blends were able to achieve self-extinction and V-1 classification; the other formulations showed a strong melt dripping and higher burning. In addition to this, cone calorimetry results showed that the most enhanced behavior was found when 10 wt % of LL and AlP were combined, which strongly reduced PHRR (-74%) and THR (-22%), due to the interaction between LL and AlP, which not only promotes char formation but also confers the stability to char in the condensed phase.

An efficient flame retardant for epoxy resin: Preparation and pyrolytic behaviour

Using 4,4-diaminodiphenyl methane as a curing agent, three kinds of monomers, 4,4′-dihydroxybenzophenone, diphenyl chlorophosphite and 1,4-phenylene diisocyanate (NCO), were introduced into a thermosetting resin (DGEBA). The flame retardancy properties of the composites were studied, and the results were compared with those of 5 wt% bis(bis(4-((diphenoxyphosphoryl)oxy)phenyl)methyl) 1,4-phenylenedicarbamate (DHPP-OH-NCO), 10 wt% DHPP-OH-NCO and 15 wt% DHPP-OH-NCO curing agents. The results showed that 15 wt% DHPP-OH-NCO had an improved flame retardancy, the limited oxygen index reached 33.5% and the vertical burning test (UL94) achieved a V-0 level. A cone calorimeter experiment showed that the addition of the flame retardant significantly reduced the amount of generated smoke and heat. Macroscopic digital images, scanning electron microscopy images and thermogravimetric analysis results further revealed that the epoxy resin (EP) with DHPP-OH-NCO exhibited greater char yields. The flame retardancy mechanism of the flame retardant was preliminarily shown by pyrolysis–gas chromatography–mass spectrometry analysis. The combined test results demonstrate that a high-efficiency phosphorous-containing flame retardant for EPs was successfully developed.

Thermal Stability of Allyl-Functional Phthalonitriles-Containing Benzoxazine/Bismaleimide Copolymers and Their Improved Mechanical Properties

Copolymerization is the typical method to obtain the high-performance resin composites, due to its universality and regulation performance. It can be employed among various resin matrices with active groups to obtain the desired structures, and subsequently, the outstanding properties. In this work, the copolymerization between the allyl-functional phthalonitrile-containing benzoxazine resin (DABA-Ph) and 4,4'-bis(Maleimidodiphenyl)methane (BMI) were monitored. The interactions among the active groups including allyl moieties, maleimide, benzoxazine rings and nitrile groups were investigated. Differential scanning calorimetry (DSC) and dynamic rheological analysis (DRA) were used to study the curing behaviors and the processing properties. The possible curing processes were proposed and confirmed by Fourier transform infrared spectroscopy (FTIR). Then, glass fiber-reinforced DABA-Ph/BMI composites were designed, and their thermal-mechanical properties were studied. Results indicated that all the composites exhibited outstanding flexural strength, flexural modulus, and high glass-transition temperatures (Tg > 450 °C). The thermal stability of the composites was studied by thermogravimetry (TGA) and evaluated by the integral program decomposition temperature (IPDT). it is believed that the excellent thermal mechanical properties and outstanding Tg as well as good thermal stability would enable the reinforced copolymer-based laminates to be applied in wider fields.