A novel flame retardant derived from DOPO and piperazine and its application in epoxy resin: Flame retardance, thermal stability and pyrolysis behavior

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.

A Comprehensive Review of Reactive Flame Retardants for Polyurethane Materials: Current Development and Future Opportunities in an Environmentally Friendly Direction

Polyurethanes are among the most significant types of polymers in development; these materials are used to produce construction products intended for work in various conditions. Nowadays, it is important to develop methods for fire load reduction by using new kinds of additives or monomers containing elements responsible for materials' fire resistance. Currently, additive antipyrines or reactive flame retardants can be used during polyurethane material processing. The use of additives usually leads to the migration or volatilization of the additive to the surface of the material, which causes the loss of the resistance and aesthetic values of the product. Reactive flame retardants form compounds containing special functional groups that can be chemically bonded with monomers during polymerization, which can prevent volatilization or migration to the surface of the material. In this study, reactive flame retardants are compared. Their impacts on polyurethane flame retardancy, combustion mechanism, and environment are described.

Preparation and Structural Analysis of a Water-Soluble Aminated Lignin

Lignin is insoluble in water, thereby limiting its use in the synthesis of adhesives. Therefore, in this study, an aminated lignin compound was prepared through a lignin amination reaction to increase the amount of raw lignin material that can be used in the synthesis of adhesives; moreover, structural analysis was conducted. The main result of this was the introduction of amino groups into phenolic hydroxyl groups in the hydrolyzing lignin from the raw lignin materials, thus generating the product of aminated lignin. The resulting particle sizes were about 100 nm, the average molecular weight was 57,627 g/mol, and the water solubility of the aminated lignin was about 0.45 g/100 mL. Therefore, the water solubility of raw lignin was greatly improved. The proposed reaction mechanism of phenolic hydroxyl groups and carboxylic acid groups in lignin is a reaction with ammonia molecules; thus, the successful introduction of amino groups generated the aminated lignin compounds. Hence, this article enriches the scientific theory of lignin reactions and provides a reference for the widespread application of raw lignin materials in the field of adhesives.

A reactive compatibilization with the compound containing four epoxy groups for polylactic acid/poly(butylene adipate-co-terephthalate)/thermoplastic starch ternary bio-composites

How to effectively improve the poor interfacial adhesion between polylactic acid/poly(butylene adipate-co-terephthalate) (PLA/PBAT) matrix and thermoplastic starch (TPS) is still a challenge. Therefore, this work aims to introduce a convenient method to enhance the performance of PLA/PBAT/TPS blend by melt reactive extrusion. Here, using 4,4'-methylene-bis(N,N-diglycidyl-aniline) (MBDG) containing four epoxy groups as a reactive compatibilizer, and respectively using 1-methylimidazole (MI) or triethylenediamine (TD) as a catalyzer, serial PLA/PBAT/TPS ternary bio-composites are successfully prepared via melt reactive extrusion. The results showed that, under the catalysis of organic base, especially MI, the epoxy groups of MBDG can effectively react with hydroxyl and carboxyl groups of PLA/PBAT and hydroxyl groups in TPS to form chain-expanded and cross-linked structures. The tensile strength of the composites is increased by 20.0 % from 21.1 MPa, and the elongation at break is increased by 182.4 % from 17.6 % owing to the chain extension and the forming of cross-linked structures. The molecular weight, thermal stability, crystallinity, and surface hydrophobicity of the materials are gradually improved with the increase of MBDG content. The melt fluidity of the composites is also improved due to the enhancement of compatibility. The obtained PLA/PBAT/TPS materials have the potential to be green plastic products with good properties.

Eco-Friendly One-Pot Supramolecular-Assembly of P-N Flame Retardant for Fire-Safe Epoxy Resin

Flame retardant treatment of epoxy resins (EP) to reduce their flammability for extending their range of applications attracts considerable attention. However, the synthesis process of conventional flame retardants is complicated and involves organic hazardous solvents. Meanwhile, how to ensure both the flame-retardant and mechanical properties is a long-standing and actual difficult problem. In this work, a supramolecular flame retardant (named ATPFR) is facilely created by one-pot reaction, using cheap and accessible raw materials in an ecologically benign aqueous solvent. ATPFR is applied to improve the fire safety of EP. With only 5 wt% ATPFR addition, EP can reach the limiting oxygen index of 28.5% and the UL-94 V-0 rating with a significant "blow-out effect." The cone calorimetry test reveals that the EP thermoset with 5 wt% ATPFR has a 75.8% reduction in the peak heat release rate (p-HRR) and a 67.3% reduction in the peak smoke production rate (p-SPR), respectively, compared with the pure EP. Additionally, EP composites with the small amount of ATPFR exhibit a slight decrease and maintain good mechanical properties. Therefore, the facile synthesis and application of this supramolecular flame retardant provide a reliable way for the construction of polymer materials with environment-friendly and effective flame-retardant system.

Design of P-decorated POSS towards flame-retardant, mechanically-strong, tough and transparent epoxy resins

Epoxy resins (EPs) are known for their durability, strength, and adhesive properties, which make them a versatile and popular material for use in a variety of applications, including chemical anticorrosion, small electronic devices, etc. However, EP is highly flammable due to its chemical nature. In this study, phosphorus-containing organic-inorganic hybrid flame retardant (APOP) was synthesized by introducing 9, 10-dihydro-9-oxa-10‑phosphaphenathrene (DOPO) into cage-like octaminopropyl silsesquioxane (OA-POSS) via Schiff base reaction. The improved flame retardancy of EP was achieved by combining the physical barrier of inorganic Si-O-Si with the flame-retardant capability of phosphaphenanthrene. EP composites containing 3 wt% APOP passed the V-1 rating with a value of LOI of 30.1% and showed an apparent reduction in smoke release. Additionally, the combination of the inorganic structure and the flexible aliphatic segment in the hybrid flame retardant provides EP with molecular reinforcement, while the abundance of amino groups facilitates a good interface compatibility and outstanding transparency. Accordingly, EP containing 3 wt% APOP increased in tensile strength, impact strength, and flexural strength by 66.0 %, 78.6 %, and 32.3 %, respectively. The EP/APOP composites had a bending angle lower than 90°, and their successful transition to a tough material highlights the potential of this innovative combination of the inorganic structure and the flexible aliphatic segment. In addition, the relevant flame-retardant mechanism revealed that the APOP promoted the formation of a hybrid char layer containing P/N/Si for EP and produced phosphorus-containing fragments during combustion, showing flame-retardant effects in both condensed and vapor phases. This research offers innovative solutions for reconciling flame retardancy & mechanical performances and strength & toughness for polymers.

A Nitrogen-Rich DOPO-Based Derivate for Increasing Fire Resistance of Epoxy Resin with Comparable Transparency

To endow synergistically epoxy resin (EP) with excellent fire resistance and high optical transparency, a nitrogen-rich DOPO-based derivate (named as FATP) was synthesized and incorporated into EP. It showed that the incorporation of the FATP reduced the fire hazard of the EP, as demonstrated by the fact that the EP/4% FATP blends gained a UL-94 V-0 rating and an LOI value of 35%, with the lowest values of the THR (86.7 MJ/m²), the PHRR (1059.3 kW/m²), and the TSP (89.6 MJ/m²). The presence of the FATP also reduced the thermal stability and the crosslinking density whilst improving the curing reaction and the storage modulus of the EP/FATP blends. The TG-FTIR spectra showed that •HPO/•PO free radicals and some nonflammable gases (HN₃ and NH₃) were produced during the pyrolysis, and the characterization (SEM, Raman spectroscopy, and XPS) of char residues confirmed that the FATP facilitated the formation of continuous and compact carbon layers of greater graphitization degree. It was thus concluded that the FATP played the flame-retardant roles in both the gas and condensed phases. Furthermore, the FREPs kept almost identical transparency as the pristine EP, and mechanical properties were also slightly enhanced. The FREPs presented in this work show promising applications in the fields of advanced optical technology.

Effect of 3-methoxysalicylaldehyde on transparency and mechanical properties of EP modified with aminopyridine-based DOPO derivative

Two effective flame retardant additives hsalaminopyridine phosphaphenanthrene (HAD) and methoaminopyridine phosphaphenanthrene (MAD) were respectively prepared with DOPO, aminopyridine, salicylaldehyde and 3-Methoxysalicylaldehyde. Subsequently, HAD and MAD was added into epoxy resin (EP) respectively, and flame retardancy of EP/HAD and EP/MAD thermosets were dramatically enhanced. The result of cone calorimeter (CC) test revealed that both HAD and MAD showed perfect smoke suppression performance. In respect of transmittance and mechanical properties, there was a huge difference between HAD and MAD. The introduction of HAD dramatically harmed transmittance and mechanical properties of EP, while, EP/10%MAD was transparent and nearly possessed the same mechanical properties with pure EP.

Fabrication of two multifunctional phosphorus–nitrogen flame retardants toward improving the fire safety of epoxy resin

To improve the fire safety of epoxy resin (EP), two novel phosphorus–nitrogen flame retardants, which named as diphenyl allylphosphoramidate (DPCA) and N-allyl-P, P-diphenylphosphinic amide (DCA), were synthesized by acyl chloride reaction and introduced into EP for fabricating EP composites. The combustion tests showed that incorporation of 5 wt% DPCA or 5 wt% DCA into EP led to the exceptional limited oxygen index (LOI) value (27.1% or 31.6%). Besides, the peak of heat release rate of EP-5 wt% DPCA and EP-5 wt% DCA was reduced by 40.69% and 36.69%, respectively, compared to pure EP. The enhanced fire resistance of EP was ascribed to the trapping effect of fillers in the gas phase and the charring effect in the condensed phase. Furthermore, ultraviolet-visible spectra revealed that both EP-5 wt% DPCA and EP-5 wt% DCA have considerable transparency. This study is expected to broaden the application of EP in the industrial area.

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.

Thermal Stability, Smoke Density, and Flame Retardance of Ecotype Bio-Based Flame Retardant Agricultural Waste Bagasse/Epoxy Composites

In the study, agricultural waste bagasse was used as a bio-based flame retardant for reducing the flammability of epoxy. Specifically, an interpenetrating network (IPN) was formed through a ring opening reaction between the hydroxyl functional group of bagasse and the epoxy group of triglycidyl isocyanurate (TGIC), forming Bagasse@TGIC. Next, 9, 10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide (DOPO) was mixed with Bagasse@TGIC, inducing a reaction between the active hydrogen of DOPO and the epoxy group of TGIC, ultimately forming Bagasse@TGIC@DOPO with an IPN structure. Finally, the novel flame retardant was added to epoxy to create a composite. The integral procedural decomposition temperature (IPDT) of pure epoxy is 619 °C; after the introduction of the 30 wt% flame retardant, the IPDT of the resultant composite material increased to 799 °C, greatly increasing the thermal stability by 29%. After the addition of the Bagasse@TGIC@DOPO flame retardant, the limiting oxygen index increased from 21% for the pure epoxy to 29% for the composite, and the UL-94 rating improved from failing rating for the pure epoxy and V-0 rating for the composite. The Raman spectrum indicated that the addition of Bagasse@TGIC@DOPO IPN substantially increased the biochar yield during the burning process, increasing thermal stability. These results confirmed that the epoxy/Bagasse@TGIC@DOPO composite had substantial flame retarding effects.

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.

Synergetic integration of thermal conductivity and flame resistance in nacre-like nanocellulose composites

Highly thermally conductive and flame resistant nanocellulose-based composites can synchronously achieve efficient thermal dissipation and low fire hazards of electronic devices, which shows great promise in next-generation green and flexible electronics. However, it has long been intractable to optimize the high thermal conductivity (TC) and flame resistance simultaneously. Herein, synergetic integration of high TC and flame resistance in nacre-like nanocellulose composites has been successfully achieved by the vacuum-assisted filtration of cellulose nanofibers (CNFs) and functionalized boron nitride nanosheets (BNNS-p-APP). Benefiting from the highly oriented hierarchical microstructure, strong hydrogen-bonding interaction, and successful immobilization of ammonium polyphosphate (APP), the as-obtained CNFs/BNNS-p-APP composite film achieves a high in-plane TC of 9.1 W m^-1 K^-1 and outstanding flame resistance. Meantime, this eco-friendly nanocellulose-based composite also exhibits remarkable flexibility, folding endurance, and mechanical robustness, robustness, which may open up a new opportunity for the thermal management of flexible electronics.

Nanostructured Surface Finishing and Coatings: Functional Properties and Applications

This review presents current literature on different nanocomposite coatings and surface finishing for textiles, and in particular this study has focused on smart materials, drug-delivery systems, industrial, antifouling and nano/ultrafiltration membrane coatings. Each of these nanostructured coatings shows interesting properties for different fields of application. In this review, particular attention is paid to the synthesis and the consequent physico-chemical characteristics of each coating and, therefore, to the different parameters that influence the substrate deposition process. Several techniques used in the characterization of these surface finishing coatings were also described. In this review the sol-gel method for preparing stimuli-responsive coatings as smart sensor materials is described; polymers and nanoparticles sensitive to pH, temperature, phase, light and biomolecules are also treated; nanomaterials based on phosphorus, borates, hydroxy carbonates and silicones are used and described as flame-retardant coatings; organic/inorganic hybrid sol-gel coatings for industrial applications are illustrated; carbon nanotubes, metallic oxides and polymers are employed for nano/ultrafiltration membranes and antifouling coatings. Research institutes and industries have collaborated in the advancement of nanotechnology by optimizing conversion processes of conventional materials into coatings with new functionalities for intelligent applications.

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.