Influence of a novel P/N-containing oligomer on flame retardancy and thermal degradation of intumescent flame-retardant epoxy resin

Synthesis and Characterization of Sodium Lignosulfonate-Based Phosphorus-Containing Intermediates and Its Composite Si-P-C Silicone-Acrylic Emulsion Coating for Flame-Retardant Plywood

Through the substitution reaction between 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) and sodium lignosulfonate (LS), a novel phosphorus-containing sodium lignosulfonate (DAL) was successfully synthesized via the solvothermal method and used as a multifunctional flame retardant to prepare a novel silicone-acrylic emulsion (SAE) composite Si-P-C coating. The structure of DAL was determined by X-ray diffraction (XRD), attenuated total reflection infrared spectroscopy (ATR-FTIR), X-ray photoelectron spectroscopy (XPS), and nuclear magnetic resonance (solid-state 13C NMR and 31P NMR). The results demonstrated that incorporating an appropriate dosage of DAL (0.9 g, 1.5 wt %) into SAE-based composite coatings enhances flame retardancy and reduces heat release and smoke production during burning. The peak heat release rate (p-HRR) decreases from 236.7 to 120.3 kW·m-2, total smoke production (TSP) decreases by 71.1%, and the flame-retardant index increases from 1.00 to 4.58. Meanwhile, the coating is transformed into a dense and nonflammable vitreous polyphosphate barrier layer during the firing process to prevent heat or mass transfer. Furthermore, the pyrolysis kinetics identify that the 3D Z-L-T model governs the coatings' pyrolysis, and the appropriate DAL makes the pyrolysis Eα climb from 300.98 to 331.30 kJ·mol-1 at 358-439 °C. Hence, this study presents a new synthesis method of multifunctional flame retardant DAL, studies the excellent properties and cross-linking mechanism of DAL-doped SAE-composite Si-P-C coatings, and explores a halogen-free, low-carbon, and clean eco-technology strategy.

Green and economic flame retardant prepared by the one-step method for polylactic acid

Resolving the flammability of poly(L-lactic acid) (PLA) while ensuring its environmental friendliness and preserving key flame retardancy and mechanical properties represents a critical challenge. We have successfully developed a highly efficient and environmentally friendly flame retardant called Hexamethylenediamine tetramethylene phosphonic acid amine (HDME). The flame retardancy of PLA/HDME composites was significantly improved, as indicated by the LOI value of 29.1 % and UL-94 V-0 rating for PLA/3.5 HDME with only 3.5 % HDME addition. The results show a 23.4 % reduction in the total heat release (THR), a 40.0 % increase in the time to ignition (TTI), and a 21.2 % increase in the flame propagation index (FPI) compared to original PLA. Flame retardant mechanism of HDME involves the gas phase, condensed phase, and interrupted heat exchange effects. The HDME also preserved the original mechanical properties of PLA, with the elongation at break and tensile strength retention of PLA/3.5 HDME reaching 93.05 % and 89.65 %. This work provides a simple and efficient method for flame retardant modification of PLA, which can expand its application scope.

A Rigid-Flexible and Multi-Siloxane Bridge Strategy for Toughening Epoxy Resin with Promising Flame Retardancy, Mechanical, and Dielectric Properties

Developing highly efficient and multifunctional epoxy resins (EPs) that overcome the shortcomings of flammability and brittleness is crucial for pursuing sustainable and safe application but remains a huge challenge. In this paper, a novel biomass-containing intumescent flame retardant containing a rigid-flexible and multi-siloxane bridge structure (DPB) was synthesized using siloxane; 9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide (DOPO); and biomass vanillin. DPB could facilitate the formation of a carbon residual with an intumescent structure, which effectively blocked the propagation of heat and oxygen. As a result, the peak heat release rate (pHRR) and total heat release (THR) of DPB/EP-7.5 decreased by 38.8% and 45.0%, respectively. In terms of mechanical properties, the tensile and flexural elongations at break of DPB/EP-7.5 increased by 77.2% and 105.3%, respectively. Impressively, DPB/EP-7.5 had excellent dielectric properties, with a dielectric constant of 2.5-2.9. This was due to the Si-O bonds (multi-siloxane bridges) contained in DPB/EP, which can quench the polarization behavior of the hydroxyl group. This paper provides a facile strategy for the preparation of multifunctional EP, which will pave the way for the promotion and application of EP in the high-end field.

Ultra-light-weight, anti-flammable and water-proof cellulosic aerogels for thermal insulation applications

Cellulosic aerogels (CNF) are considered naturally available thermal insulating materials as substitutes for conventional polymeric aerogels owing to their extensive sources, low density, low thermal conductivity, sustainability and biodegradability. However, cellulosic aerogels suffer from high flammability and hygroscopicity. In this work, a novel P/N-containing flame retardant (TPMPAT) was synthesized to modify cellulosic aerogels to improve their anti-flammability. TPMPAT/CNF aerogels were further modified by polydimethylsiloxane (PDMS) to enhance the water-proof characteristics. Although the addition of TPMPAT and/or PDMS slightly increased the density and thermal conductivity of the composite aerogels, those values were still comparable to the commercial polymeric aerogels. Compared with pure CNF aerogel, the cellulose aerogel modified by TPMPAT and/or PDMS had higher T-10%, T-50% and Tmax, which indicated that the modified cellulose aerogels have better thermal stability. TPMPAT modification made CNF aerogels highly hydrophilic, while TPMPAT/CNF aerogel modified by PDMS became a highly hydrophobic material with a water contact angle (WCA) of 142°. Pure CNF aerogel burned rapidly after ignition, showing a low limiting oxygen index (LOI) of 23.0% and no UL-94 grade. In contrast, both TPMPAT/CNF-30% and PDMS-TPMPAT/CNF-30% showed self-extinction behaviors with a UL-94 V-0 grade, implying high fire resistance. Combined with high anti-flammability and hydrophobicity, the ultra-light-weight cellulosic aerogels show great potential for thermal insulation applications.

Synergistic Flame Retardant Effect between Ionic Liquid Functionalized Imogolite Nanotubes and Ammonium Polyphosphate in Epoxy Resin

Ionic liquid functionalized imogolite nanotubes (INTs-PF6-ILs) were introduced into the epoxy resin (EP)/ammonium polyphosphate (APP) system to investigate the flame retardant performance and thermal properties using the limiting oxygen index (LOI) test, the UL-94 test, and the cone calorimeter test (CCT). The results suggested that a synergistic effect exists between INTs-PF6-ILs and APP on the char formation and anti-dripping behavior of EP composites. For the EP/APP, an UL-94 V-1 rating was obtained for the loading of 4 wt% APP. However, the composites containing 3.7 wt% APP and 0.3 wt% INTs-PF6-ILs could pass the UL-94 V-0 rating without dripping behavior. In addition, compared with the EP/APP composite, the fire performance index (FPI) value and fire spread index (FSI) value of EP/APP/INTs-PF6-ILs composites were remarkably reduced by 11.4% and 21.1%, respectively. Moreover, the char formed by EP/APP composites was intumescent, but of poor quality. In contrast, the char for EP/APP/INTs-PF6-ILs was strong and compact. Therefore, it can resist the erosion due to heat and gas formation and protect the inside of the matrix. This was the main reason for the good flame retardant property of EP/APP/INTs-PF6-ILs composites.

Flame-retardant effect of tannic acid-based intumescent fire-retardant applied on flammable natural rubber

Tannic acid (TA) is a natural phenolic compound abundant in plants. Its characteristics of low combustion and good absorption make it useful in the flame retardant field. On this basis, a new expansive flame retardant system (ACT) composed of ammonium polyphosphate (APP)/TA functional clay (CT) was used to study the synergistic flame retardancy and smoke suppression of natural rubber (NR). Because of their unique flame retardancy and better mechanical properties compared with the traditional expansive flame retardant system (IFR), new flame retardants have attracted much attention in various fields. The results of the cone calorimeter showed that the ACT system can significantly influence the decomposition behavior of NR and form a highly graphitized and phosphorous carbon layer to protect the composite material, thus a synergistic effect is produced on the flame retardancy and smoke suppression performance of the composite material. In addition, within the effective additive quality range of the ACT system, TC can give the NR composite excellent mechanical properties.

The ACT systems give synergistic effects on the flame retardancy and smoke suppression properties of NR.

Enhanced fire-proofing performance and crystallizability of bio-based poly(L-lactic acid): Dual functions of a Schiff base-containing synergistic flame retardant

Poly(L-lactic acid) (PLA) is a kind of important bio-macromolecule which can be prepared via fermentation of starch of maize and sweet potato. Flammability and extremely poor crystallizability limited its wide application. In this work, a novel Schiff base derivate (CP) was synthesized and, combined with ammonium polyphosphate (APP) as a synergistic flame retardant and nucleating agent to investigate its effects on LOI, UL-94 rating, thermal stability, combustion behavior and crystallizability of PLA. With loading of 5%CP/10%APP, PLA showed a significantly enhanced LOI and passed V-0 fire-safety rating with self-extinguish effect. PLA/5%CP/10%APP presented the lowest pHRR, THR and TSR, and highest char residue yield, FPI and FRI in cone calorimetry test, indicating an excellent flame retardancy effect, enhanced fire safety and longer escaping time in the fire. A continuous, compact and thick char layer structure formed as a protective barrier in combustion process, to enhance heat-insulating and oxygen resistance property, thermal stability and smoke-suppressing capacity of PLA. Flame retardancy mechanism was proposed and discussed based on comprehensive and in-depth characterization techniques. Also, 5%CP/10%APP presented a good nucleation effect to enormously increase crystallizability and shorten crystallization time of PLA.

From herbicide to flame retardant: The lamellar-like phosphorus-bridged amitrole toward high fire safety epoxy resin with light smoke and low toxicity

In an attempt to alleviate the harmful impact of the flammability of epoxy resin on the environment, amitrole, a herbicide, has been converted to a novel flame retardant (PBA) with lamellar morphology through organophosphorus modification. This material has been utilized to fabricate fire safe epoxy thermosets (EP). EP containing 7.5 wt% PBA undergoes quick self-extinguishment upon ignition. This blend displays a high limiting oxygen index (LOI) value of 34%. More importantly, hazardous products (heat, smoke, toxic gases including CO/CO₂) released during combustion of EP, are strongly suppressed in the presence of PBA. The mechanical properties of EP-PBA blends are comparable to those of virgin EP. The tensile strength of EP containing PBA is 90% of that of unmodified EP. The flexural strength of PBA blends is somewhat greater than that for EP containing no additive. A tactful strategy for the transformation of amitrole, a potential environmental contaminant to a benign flame retardant for polymers has been developed.

A Study of Thermal Degradation and Fire Behaviour of Polymer Composites and Their Gaseous Emission Assessment

The use of polymer composite materials in the aeronautics and automotive sectors has increased dramatically, and their fire behaviour has become a critical parameter in terms of fire safety. On this premise, it is critical to demonstrate that these composite materials constitute elements whose safety justifies a high level of confidence. This is based on their combustibility and the rate at which flammable and toxic gaseous species are emitted. Thus, strict fire safety regulations are enforced by the relevant authorities concerned because of their potential fire risk. This study analysed papers published between 1970 and 2021 that described the devices used to characterise the thermal behaviour of composite materials at various scales. The objective was to highlight the thermophysical phenomena, making it possible to accurately assess the flammability and thermal stability of polymer composite materials. The results of this research reveal that the small-scale facilities provide detailed understanding and mastery of the thermal reaction properties of the composites. While with the medium scale, the extended fire reaction parameters, which are the key indicators of the fire safety performance, can be determined. On a large scale, the tests were carried out using devices such as the NexGen burner recommended by the FAA. Therefore, with such assays, it is possible to assess the rates of thermal degradation as well as quantified pyrolysis gases. However, compared to other scales, there were very few works on a large scale. In addition, by focusing on the polluting nature of synthetic composite materials, there is also few research studies aimed at designing new polymer composite materials from biological sources.

Discotic Liquid Crystal Epoxy Resins Integrating Intrinsic High Thermal Conductivity and Intrinsic Flame Retardancy

The integration of intrinsic thermal conductivity and intrinsic flame retardancy of epoxy resins shows wider application prospects in electricals and electronics. Discotic liquid crystal epoxy (D-LCE) is synthesized from pyrocatechol, 2-allyloxyethanol, and 3-chloroperoxybenzoic acid. P/Si synergistic flame-retardant co-curing agent (DOPO-POSS, DP) is synthesized from p-hydroxybenzaldehyde, 9, 10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide (DOPO), and amino terminated polysilsesquioxane (POSS). Finally, D-LCE is cured within liquid crystal range with 4, 4'-diaminodiphenyl methane (DDM) and DP, to obtain intrinsic highly thermal conductive/flame-retardant epoxy resins (D-LCER_DP ). D-LCER_DP-10.0 (10.0 wt% DP) synchronously possesses excellent intrinsic thermal conductivity and intrinsic flame retardancy, with thermal conductivity coefficient in vertical and parallel direction (λ_⊥ and λ_∥ ) of 0.34 and 1.30 W m^-1 K^-1 , much higher than that of general bisphenol A epoxy resin (E-51, λ_⊥ of 0.19 W m^-1 K^-1 , λ_∥ of 0.65 W m^-1 K^-1 ). The limiting oxygen index (LOI) value of D-LCER_DP-10.0 reaches 31.1, also better than those of E-51 (19.8) and D-LCER (21.3).

A phosphorus-containing hyperbranched phthalocyanine flame retardant for epoxy resins

A hyperbranched phosphorus-containing copper phthalocyanine compound (DOPO-CuPc) was successfully synthesized and used as the flame-retardant additive to prepare flame-retarded epoxy thermosets. The addition of DOPO-CuPc led to a significant enhancement of the flame retardant properties of the epoxy resin. The 15DOPO-CuPc/EP composite obtained a LOI value of 35.8%, and the UL-94 rose from NR to V-0 rating. And the addition of DOPO-CuPc resulted in early decomposition of the epoxy thermoset, but the residual char at 700 °C reached 27.7%. The flame retardant mechanism was further investigated. It was found that DOPO-CuPc could release phosphorus-containing radicals and non-combustible gases in the gas phase to exert gas-phase flame retardant activity. In the condensed phase, the epoxy thermoset formed the expanded honeycomb-like char layer during combustion and the presence of copper phthalocyanine contributed to the stability of the char layer.

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.

Preparation of a novel functionalized magnesium-based curing agent as an intrinsic flame retardant for epoxy resin

In this study, a novel organic-inorganic hybrid flame retardant 10-(1,4-dicarboxylic acid magnesium salt)-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DMMH) was synthesized via neutralization and addition reaction of maleic acid, magnesium hydroxide and 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO), and subsequently used in an intrinsic flame retardant epoxy resin. The chemical structure and morphology of DMMH were analyzed by Fourier transform infrared spectroscopy (FTIR), X-ray photoelectron spectroscopy (XPS) and scanning electron microscopy (SEM). Further, the prepared DMMH was combined with ammonium polyphosphate (APP) to form an intumescent flame retardant system. The thermal stability and flame retardance were evaluated by thermogravimetric analysis (TG), UL-94 vertical burning test, limiting oxygen index (LOI) and cone calorimetry. It was observed that the addition of 1.7% DMMH and 5.3% APP led EP-7 to acquire UL-94 V-0 rating, with the limiting oxygen index of 26.0%. As compared with pure EP, the peak heat release rate, total heat release, smoke production rate and total smoke production of the sample was noted to decrease by 54.5%, 35.1%, 43.6% and 38.1%, respectively. In addition, the introduction of DMMH did not negatively impact the mechanical properties of the epoxy resin.

Towards Selection Charts for Epoxy Resin, Unsaturated Polyester Resin and Their Fibre-Fabric Composites with Flame Retardants

Epoxy and unsaturated polyester resins are the most used thermosetting polymers. They are commonly used in electronics, construction, marine, automotive and aircraft industries. Moreover, reinforcing both epoxy and unsaturated polyester resins with carbon or glass fibre in a fabric form has enabled them to be used in high-performance applications. However, their organic nature as any other polymeric materials made them highly flammable materials. Enhancing the flame retardancy performance of thermosetting polymers and their composites can be improved by the addition of flame-retardant materials, but this comes at the expense of their mechanical properties. In this regard, a comprehensive review on the recent research articles that studied the flame retardancy of epoxy resin, unsaturated polyester resin and their composites were covered. Flame retardancy performance of different flame retardant/polymer systems was evaluated in terms of Flame Retardancy index (FRI) that was calculated based on the data extracted from the cone calorimeter test. Furthermore, flame retardant selection charts that relate between the flame retardancy level with mechanical properties in the aspects of tensile and flexural strength were presented. This review paper is also dedicated to providing the reader with a brief overview on the combustion mechanism of polymeric materials, their flammability behaviour and the commonly used flammability testing techniques and the mechanism of action of flame retardants.

Hydrogen Bond Association to Prepare Flame Retardant Polyvinyl Alcohol Film with High Performance

It has always been the goal of flame retardant research to improve the flame retardancy of a polymer efficiently without compromising comprehensive properties such as mechanical properties. For polyvinyl alcohol (PVA), inspired by the multiple hydrogen bonding in spider silk, we design a new type of compound containing phosphorus and nitrogen with multiple hydrogen-bonding reaction sites (N,N',N''-tris(2-aminoethyl)phosphoric triamide (TE)) as it is flame retardant. The dynamic cross-linking structure is constructed, and the hyperdispersion of flame retardancy is achieved by the hydrogen bond self-assembly between TE and PVA, thus the high-performance flame retardant PVA is obtained. With only a 10 wt % addition of TE, the PVA film with a thickness of 0.15 mm can reach the UL94 VTM-0 level, and its tensile strength, ductility, and initial decomposition temperature can be increased by 33, 15, and 12 °C, respectively. In addition, the hydrogen-bonding effect and flame retardant mechanism are characterized and studied. This work overcomes the shortcomings of traditional flame retarding approaches and provides an effective strategy for the preparation of flame retardant polymers with an excellent performance.

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.

Nanoflake-Constructed Supramolecular Hierarchical Porous Microspheres for Fire-Safety and Highly Efficient Thermal Energy Storage

The leakage and fire hazard of organic solid-liquid phase change material (PCM) tremendously limit its long-term and safe application in thermal energy storage and regulation. In this work, novel nanoflake-fabricated organic-inorganic supramolecular hierarchical microspheres denoted as BPL were synthesized through the electrostatically driven assembly of poly(ethylene ammonium phenylphosphamide) (BP) decorated layered double hydroxides using sodium dodecyl sulfate as a template. Then the BPL was simultaneously utilized as a porous supporting material and flame retardant for polyethylene glycol to fabricate shape-stabilized PCM (BS-PCM). Benefiting from the structural uniqueness of the BPL microsphere, the BS-PCM possessed a high latent heat capacity of 116.7 J g^-1 and excellent thermoregulatory capability. Moreover, the BS-PCM had no apparent leakage after a 200-cycle heating/cooling process and showed excellent thermal reversibility, superior to similar solid-liquid PCMs reported in recent literature. More interestingly, unlike flammable PEG, BS-PCM showed excellent fire resistance when exposed to a fire source. The unique BPL porous microsphere provided not only a microcontainer with high storage capacity for solid-liquid PCM, but also a fire resistant barrier to PEG, supplying a promising solution for highly efficient and fire-safe thermal energy storage.

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.

Improving the flame retardancy of waterborne polyurethanes based on the synergistic effect of P-N flame retardants and a Schiff base

A novel reactive intumescent fire retardant hexa-[4-[(2-hydroxy-ethylimino)-methyl]-phenoxyl]-cyclotriphosphazene (HEPCP), containing both cyclotriphosphazene and Schiff base structures, is successfully prepared. The chemical structures of HEPCP and flame-retardant waterborne polyurethane (WPU) (FR-WPU) were characterized via³¹P, ¹H NMR and FT-IR. Thermogravimetric (TG) analysis showed that HEPCP exhibited excellent thermal stability and produced rich char residue under high temperature compared with the control sample. The Schiff base and cyclotriphosphazene had a synergistic effect on the WPU. Limiting oxygen index (LOI) values of up to 26.7% were recorded; the dripping behavior was simultaneously improved and achieved a V-1 rating in the UL-94 test by incorporating 0.5 wt% phosphorus. In contrast to the pure WPU, the peak heat release rate (pHRR) of the FR-WPU/HEPCP5 decreased by 43.8%. The char residues increased from 0.63% to 6.96%, and scanning electron microscopy (SEM) showed a relatively continuous and membranous substance, with few holes. The results of TGA-FIR, Py-GC/MS and SEM indicated that HEPCP displayed a fire-retardant mechanism in the condensed-phase. In addition, the thermomechanical behaviors and the mechanical properties indicated that both mechanical properties and T_gh increased.

A novel reactive intumescent fire retardant hexa-[4-[(2-hydroxy-ethylimino)-methyl]-phenoxyl]-cyclotriphosphazene (HEPCP), containing both cyclotriphosphazene and Schiff base structures, is successfully prepared.