Electrostatic action induced interfacial accumulation of layered double hydroxides towards highly efficient flame retardance and mechanical enhancement of thermoplastic polyurethane/ammonium polyphosphate

Construction of Fire Safe Thermoplastic Polyurethane/Reduced Graphene Oxide Hierarchical Composites with Electromagnetic Interference Shielding

Incorporating outstanding flame retardancy and electromagnetic interference shielding effectiveness (EMI SE) into polymers is a pressing requirement for practical utilization. In this study, we first employed the principles of microencapsulation and electrostatic interaction-driven self-assembly to encapsulate polyethyleneimine (PEI) molecules and Ti3C2Tx nanosheets on the surface of ammonium polyphosphate (APP), forming a double-layer-encapsulated structure of ammonium polyphosphate (APP@PEI@Ti3C2Tx). Subsequently, flame-retardant thermoplastic polyurethane (TPU) composites were fabricated by melting the flame-retardant agent with TPU. Afterwards, by using air-assisted thermocompression technology, we combined a reduced graphene oxide (rGO) film with flame-retardant TPU composites to fabricate hierarchical TPU/APP@PEI@Ti3C2Tx/rGO composites. We systematically studied the combustion behavior, flame retardancy, and smoke-suppression performance of these composite materials, as well as the flame-retardant mechanism of the expansion system. The results indicated a significant improvement in the interface interaction between APP@PEI@Ti3C2Tx and the TPU matrix. Compared to pure TPU, the TPU/10APP@PEI@1TC composite exhibited reductions of 84.1%, 43.2%, 62.4%, and 85.2% in peak heat release rate, total heat release, total smoke release, and total carbon dioxide yield, respectively. The averaged EMI SE of hierarchical TPU/5APP@PEI@1TC/rGO also reached 15.53 dB in the X-band.

Calcium gluconate-based flame retardant towards simultaneously high-efficiency fire safety and mechanical enhancement for epoxy resin

Flame retardants containing biomass receive growing interest in environmental friendliness and sustainability but usually face the low flame-retardant efficiency and deterioration on mechanical property of matrix. Herein, a calcium gluconate-based flame retardant (CG@APP) was chemically prepared using calcium gluconate (CG) and ammonium polyphosphate (APP) via ion exchange reaction, and enabled the excellent fire safety and mechanical enhancement for epoxy resin (EP). The resulted EP composites containing 6 wt% CG@APP (EP/CG@APP6) exhibited V-0 ratings in UL-94 test. Furthermore, with respect to EP/APP6, the peak of heat release rate (pHRR) and peak of smoke production rate (pSPR) of EP/CG@APP6 decreased by 70.5 % and 50.0 %, respectively. The well synergistic flame-retardant mechanism of CG@APP between gaseous and solid phases was revealed to generate denser and more continuous charring residuals, which could do well work on insulation for heat transfer and fuel diffusion. In addition, the shell rich in hydroxyl group and Ca2+ on the surface of CG@APP well enhanced the interface compatibility through the hydrogen bond and coordinated bond, thus the tensile strength, flexural strength and impact strength of EP/CG@APP6 increased by 18.2 %, 4.5 % and 9.1 % compared with pure EP, respectively. This work provided a simple and sustainable way to construct excellent fire-safety composites.

Balanced Thermal Insulation, Flame-Retardant and Mechanical Properties of PU Foam Constructed via Cost-Effective EG/APP/SA Ternary Synergistic Modification

To address the challenge of balancing the mechanical, thermal insulation, and flame-retardant properties of building insulation materials, this study presented a facile approach to modify the rigid polyurethane foam composites (RPUFs) via commercial expandable graphite (EG), ammonium polyphosphate (APP), and silica aerogel (SA). The resulting EG/APP/SA/RPUFs exhibited low thermal conductivity close to neat RPUF. However, the compressive strength of the 6EG/2APP/SA/RPUF increased by 49% along with achieving a V-0 flame retardant rating. The residual weight at 700 °C increased from 19.2 wt.% to 30.9 wt.%. Results from cone calorimetry test (CCT) revealed a 9.2% reduction in total heat release (THR) and a 17.5% decrease in total smoke production (TSP). The synergistic flame-retardant mechanism of APP/EG made significant contribution to the excellent flame retardant properties of EG/APP/SA/RPUFs. The addition of SA played a vital role in reducing thermal conductivity and enhancing mechanical performance, effectively compensating for the shortcomings of APP/EG. The cost-effective EG/APP/SA system demonstrates a positive ternary synergistic effect in achieving a balance in RPUFs properties. This study provides a novel strategy aimed at developing affordable building wall insulation material with enhanced safety features.

Realizing balanced flame retardancy and electromagnetic interference shielding in hierarchical elastomer nanocomposites

The combination of electromagnetic interference (EMI) shielding performance and flame-retardant property is essential for applications in the field of electronics and electrics. To date, there have been few successful cases in achieving such portfolios, due to the different mechanisms and even mutual exclusivity of these two attributes. Herein, an ammonium polyphosphate@chitosan@carbon nanotube (APP@CS@MWCNT) core-multishell hybrid was synthesized by microencapsulation technology. Then, the hybrid was introduced into TPU matrix to fabricate TPU composites, acting as surface layer. Meanwhile, MXene film was used as intermediate layer to construct hierarchical TPU composites. The obtained results showed that after introduction of 1 wt% APP@CS@MWCNT hybrid, the peak of heat release rate (PHRR) and the peak of smoke produce rate (PSPR) of TPU composites decreased by 67.4% and 35.6%, respectively, compared with those of pure TPU. Owing to multiple reflection losses, interface polarization losses, and charge carrier movement-induced thermal dissipation, TPU/15AC@4M-SW exhibited the highest EMI shielding performance, and obtained shielding effectiveness values of 35.7 dB and 38.9 dB in X band and K band, respectively.

LDH@Boronate Polymer Core-Shell Nanoparticles: Nanostructure Design for Synergistically Enhancing the Flame Retardancy of Epoxy Resin

As a promising nanofiller, layered double hydroxides (LDHs) can advance the fire safety of epoxy resin (EP), but so far, due to the problems of dispersion and low efficiency, it has still been a challenge to incorporate the flame retardancy and mechanical properties of EP nanocomposites effectively under the circumstance of a low additive amount. In this work, we take LDHs as the template, via the adsorption of a catechol group and the condensation polymerization between catechol groups and phenylboric acid groups, to prepare a core-shell structured nanoparticle LDH@BP, which contains rich flame-retardant elements. EP/LDH@BP nanocomposites were prepared by introducing LDH@BP into EP. The experimental results indicate that, compared with the original LDH, LDH@BP disperses uniformly in the EP matrix, and the flame retardancy and mechanical properties of EP/LDH@BP are significantly improved. At a relatively low content (5 wt%), EP/LDH@BP reached the rating of V-0 in the UL-94 test, LOI was increased to 29.1%, and peak heat release rate (PHRR) was reduced by 35.9% in cone calorimeter tests, which effectively inhibited the release of heat and toxic smoke during the combustion process of EP. Simultaneously, the mechanical properties of EP/LDH@BP have been improved satisfactorily. The above results derive from the reasonable architectural design of organic-inorganic nano-hybrid flame retardants and provide a novel method for the construction of efficient and balanced EP nanocomposite system with LDHs.

Study on the Flammability, Crystal Behaviors and Mechanical Performance of Polyamide 11 Composites by Intercalated Layered Double Hydroxides

Sulfamic acid-intercalated MgAl-LDH (SA-LDH) was prepared by an anion exchange method, and its structure was characterized by X-ray diffraction (XRD) and Fourier transform infrared spectroscopy (FTIR). SA-LDH was introduced into polyamide 11 (PA11) by melt blending and to enhance the flame retardancy and mechanical properties. The scanning electron microscope (SEM) and XRD data showed that the lamellar structure of SA-LDH was partly disrupted. The cone calorimeter (CCT) results demonstrated that SA-LDH could effectively decrease the value of heat release rate, which may be ascribed to the better distribution of SA-LDH compared to LHD in the PA11 matrix. The effects of SA-LDH on the crystal behaviors of PA11 were investigated by XRD and differential scanning calorimetry (DSC), indicating that SA-LDH could induce the formation of new crystal forms and served as a heterogeneous nucleating agent. The mechanical progress caused by the incorporation of SA-LDH was correlated with compatibility improvement between SA-LDH and PA11.

Barrier function of graphene for suppressing the smoke toxicity of polymer/black phosphorous nanocomposites with mechanism change

Recently, black phosphorous (BP) nanosheets as an emerging nanomaterial have presented significant fire safety improvement in polymer nanocomposites. However, as elemental phosphorus, fire safety improvement effect of BP nanosheets on polymer composites builds on the conversion of gaseous pyrolysis products into smoke particles, which inevitably promotes the formation and release of smoke particles. From the perspective of overall fire safety improvement, it is vital to simultaneously suppress the heat release and smoke production of polymer/BP composites. Herein, melamine-mediated graphene/black phosphorous nanohybrids (GNS/MA/BP) were fabricated through electrostatic-driving self-assembly process and introduced into polyether thermoplastic polyurethane (TPU). During combustion, the barrier function provided by thermally stable layered structure of graphene (GNS) enables more pyrolysis products of BP nanosheets to be kept within condensed phase and react with polymer matrix. Compared to pure TPU, the incorporated hierarchical nanostructure (GNS/MA/BP-2) decreases PHRR, THR, and total CO₂ release of TPU composite by 54.7%, 23.5%, and 32.5%, respectively. Beside, in contrast to TPU-BP composite, the release rate of toxic smoke and CO gas of TPU-GNS/MA/BP-2 composite are reduced by 46.7% and 49.4%. With barrier function of graphene, the heat and smoke release behavior of polymer/BP nanocomposites is effectively suppressed.

Morphology, Thermal Stability, and Flammability Properties of Polymer-Layered Double Hydroxide (LDH) Nanocomposites: A Review

The utilization of layered nanofillers in polymer matrix, as reinforcement, has attracted great interest in the 21st century. This can be attributed to the high aspect ratios of the nanofillers and the attendant substantial improvement in different properties (i.e., increased flammability resistance, improved modulus and impact strength, as well as improved barrier properties) of the resultant nanocomposite when compared to the neat polymer matrix. Amongst the well-known layered nanofillers, layered inorganic materials, in the form of LDHs, have been given the most attention. LDH nanofillers have been employed in different polymers due to their flexibility in chemical composition as well as an adjustable charge density, which permits numerous interactions with the host polymer matrices. One of the most important features of LDHs is their ability to act as flame-retardant materials because of their endothermic decomposition. This review paper gives detailed information on the: preparation methods, morphology, flammability, and barrier properties as well as thermal stability of LDH/polymer nanocomposites.

Core-Shell Graphitic Carbon Nitride/Zinc Phytate as a Novel Efficient Flame Retardant for Fire Safety and Smoke Suppression in Epoxy Resin

Novel core-shell graphitic carbon nitride/zinc phytate (g-C₃N₄/PAZn) flame retardant was simple synthetized using two-dimensional g-C₃N₄ and bio-based PAZn by self-assembly and incorporated into epoxy resin (EP) for improving the fire safety. The flame retardance and smoke suppression were investigated by cone calorimetry. The results indicated that g-C₃N₄/PAZn-EP displayed outstanding flame retardancy and smoke suppression, for example, the peak heat release rate and peak smoke production rate decreased by 71.38% and 25%, respectively. Furthermore, the flame retardancy mechanism was further explored by char residue and thermal stability analysis. It can be predicted that g-C₃N₄/PAZn will provide valuable reference about bio-based flame retardant.