Fire retardancy of polypropylene/flax blends

Ultrahigh Heat/Fire-Resistant, Mechanically Robust, and Closed-Loop Chemical Recyclable Polycarbonate Enabled by Facile Bond Dissociation Energy Modulation

Plastics serve as an essential foundation in contemporary society. Nevertheless, meeting the rigorous performance demands in advanced applications and addressing their end-of-life disposal are two critical challenges that persist. Here, an innovative and facile method is introduced for the design and scalable production of polycarbonate, a key engineering plastic, simultaneously achieving high performance and closed-loop chemical recyclability. The bisphenol framework of polycarbonate is strategically adjusted from the low-bond-dissociation-energy bisphenol A to high-bond-dissociation-energy 4,4'-dihydroxydiphenyl, in combination with the incorporation of polysiloxane segments. As expected, the enhanced bond dissociation energy endows the polycarbonate with an extremely high glow-wire flammability index surpassing 1025 °C, a 0.8 mm UL-94 V-0 rating, a high LOI value of 39.2%, and more than 50% reduction of heat and smoke release. Furthermore, the π-π stacking interactions within biphenyl structures resulted in a significant enhancement of mechanical strength by as more as 37.7%, and also played a positive role in achieving a lower dielectric constant. Significantly, the copolymer exhibited outstanding closed-loop chemical recyclability, allowing for facile depolymerization into bisphenol monomers and the repolymerized copolymer retains its high heat and fire resistance. This work provides a novel insight in the design of high-performance and closed-loop chemical recyclable polymeric materials.

The Impact of β-Radiation Crosslinking on Flammability Properties of PA6 Modified by Commercially Available Flame-Retardant Additives

A comparative study was conducted investigating the influence of β-radiation crosslinking (β-RC) on the fire behavior of flame retardant-modified polyamide 6 (PA6). In order to provide a comprehensive overview, a variety of commercially available flame-retardant additives were investigated, exhibiting different flame retarding actions such as delusion, char formation, intumescence and flame poisoning. This study focused on the identification of differences in the influence of β-RC on fire behavior. Coupled thermal gravimetrical analysis (TGA) and Fourier transformation infrared spectroscopy (FTIR) were used to conduct changes within the decomposition processes. Dynamic thermal analysis (DTA) was used to identify structural stability limits and fire testing was conducted using the limiting oxygen index (LOI), vertical UL-94 and cone calorimeter testing. Crosslinking was found to substantially change the fire behavior observed, whereas the observed phenomena were exclusively physical for the given formulations studied: warpage, char residue destruction and anti-dripping. Despite these phenomena being observed for all β-RC formulations, the impact on fire resistivity properties were found to be very different. However, the overall fire protection properties measured in UL-94 fire tests were found to deteriorate for β-RC formulations. Only β-RC formulations based on PA6/EG were found to achieve a UL-94 V0 classification.

Thermomechanical and Fire Properties of Polyethylene-Composite-Filled Ammonium Polyphosphate and Inorganic Fillers: An Evaluation of Their Modification Efficiency

The development of new polymer compositions characterized by a reduced environmental impact while lowering the price for applications in large-scale production requires the search for solutions based on the reduction in the polymer content in composites' structure, as well as the use of fillers from sustainable sources. The study aimed to comprehensively evaluate introducing low-cost inorganic fillers, such as copper slag (CS), basalt powder (BP), and expanded vermiculite (VM), into the flame-retarded ammonium polyphosphate polyethylene composition (PE/APP). The addition of fillers (5-20 wt%) increased the stiffness and hardness of PE/APP, both at room and at elevated temperatures, which may increase the applicability range of the flame retardant polyethylene. The deterioration of composites' tensile strength and impact strength induced by the presence of inorganic fillers compared to the unmodified polymer is described in detail. The addition of BP, CS, and VM with the simultaneous participation of APP with a total share of 40 wt% caused only a 3.1, 4.6, and 3 MPa decrease in the tensile strength compared to the reference value of 23 MPa found for PE. In turn, the cone calorimeter measurements allowed for the observation of a synergistic effect between APP and VM, reducing the peak heat rate release (pHRR) by 60% compared to unmodified PE. Incorporating fillers with a similar thermal stability but differing particle size distribution and shape led to additional information on their effectiveness in changing the properties of polyethylene. Critical examinations of changes in the mechanical and thermomechanical properties related to the structure analysis enabled the definition of the potential application perspectives analyzed in terms of burning behavior in a cone calorimetry test. Adding inorganic fillers derived from waste significantly reduces the flammability of composites with a matrix of thermoplastic polymers while increasing their sustainability and lowering their price without considerably reducing their mechanical properties, which allows for assigning developed materials as a replacement for flame-retarded polyethylene in large-scale non-loaded parts.

Expandable Graphite for Flame Retardant PA6 Applications

A new expandable graphite (EG) type was studied as a flame retardant additive in Polyamide 6 (PA6). The fire behavior was characterized by a cone calorimeter using external heat fluxes of 35, 50 and 65 kW/m², limiting the oxygen index (LOI) and UL-94 burning tests. Additionally, electric and thermal conductivity as well as rheological properties were characterized to provide a general property overview. Fire tests were conducted using dry and humid conditioned samples. Cone Calorimeter tests showed a minimum filling degree of 15 wt.% (8.6 vol.%) EG was required to achieve a significant fire inhibiting effect in PA6 independent of the sample condition. UL-94 fire tests show a V0 classification at filling degrees greater than 20 wt.% (humid) and 25 wt.% (dry), although the associated LOI values of 39% and 38% demonstrate good flammability inhibition. Correlation analyses were conducted to identify major influences given by the sample condition for most important key figures measured in cone calorimeter tests. Accordingly, humid-conditioned samples containing between 2.5 (PA6 + 25 wt.% EG) and 4.2 wt.% (PA6) water were found to reduce the total heat evolved (THE) on average by 16% and the total smoke production (TSP) on average by 22%.

Progress in Biodegradable Flame Retardant Nano-Biocomposites

This paper summarizes the results obtained in the course of the development of a specific group of biocomposites with high functionality of flame retardancy, which are environmentally acceptable at the same time. Conventional biocomposites have to be altered through different modifications, to be able to respond to the stringent standards and environmental requests of the circular economy. The most commonly produced types of biocomposites are those composed of a biodegradable PLA matrix and plant bast fibres. Despite of numerous positive properties of natural fibres, flammability of plant fibres is one of the most pronounced drawbacks for their wider usage in biocomposites production. Most recent novelties regarding the flame retardancy of nanocomposites are presented, with the accent on the agents of nanosize (nanofillers), which have been chosen as they have low or non-toxic environmental impact, but still offer enhanced flame retardant (FR) properties. The importance of a nanofiller’s geometry and shape (e.g., nanodispersion of nanoclay) and increase in polymer viscosity, on flame retardancy has been stressed. Although metal oxydes are considered the most commonly used nanofillers there are numerous other possibilities presented within the paper. Combinations of clay based nanofillers with other nanosized or microsized FR agents can significantly improve the thermal stability and FR properties of nanocomposite materials. Further research is still needed on optimizing the parameters of FR compounds to meet numerous requirements, from the improvement of thermal and mechanical properties to the biodegradability of the composite products. Presented research initiatives provide genuine new opportunities for manufacturers, consumers and society as a whole to create a new class of bionanocomposite materials with added benefits of environmental improvement.

Flame Retardancy of Biobased Composites-Research Development

Due to the thermal and fire sensitivity of polymer bio-composite materials, especially in the case of plant-based fillers applied for them, next to intensive research on the better mechanical performance of composites, it is extremely important to improve their reaction to fire. This is necessary due to the current widespread practical use of bio-based composites. The first part of this work relates to an overview of the most commonly used techniques and different approaches towards the increasing the fire resistance of petrochemical-based polymeric materials. The next few sections present commonly used methods of reducing the flammability of polymers and characterize the most frequently used compounds. It is highlighted that despite adverse health effects in animals and humans, some of mentioned fire retardants (such as halogenated organic derivatives e.g., hexabromocyclododecane, polybrominated diphenyl ether) are unfortunately also still in use, even for bio-composite materials. The most recent studies related to the development of the flame retardation of polymeric materials are then summarized. Particular attention is paid to the issue of flame retardation of bio-based polymer composites and the specifics of reducing the flammability of these materials. Strategies for retarding composites are discussed on examples of particular bio-polymers (such as: polylactide, polyhydroxyalkanoates or polyamide-11), as well as polymers obtained on the basis of natural raw materials (e.g., bio-based polyurethanes or bio-based epoxies). The advantages and disadvantages of these strategies, as well as the flame retardants used in them, are highlighted.

Flax/PP and Flax/PLA Thermoplastic Composites: Influence of Fire Retardants on the Individual Components

This study is based on previously reported reaction to fire properties of flax fibre-reinforced polymeric (polypropylene, PP and polylactic acid, PLA) composites, prepared by pre-treating the fabrics with different fire retardants (FRs) prior to composite preparation. It was observed that while all of these treatments were very effective in flax/PLA in terms of achieving a V-0 rating in a UL-94 test, only an organophosphonate FR was capable of achieving a V-0 rating for flax/PP. However, all fire-retardant treatments impaired the mechanical properties of the composites; the reduction was more in flax/PLA compared to flax/PP composites. To understand these effects further, here thermal analysis and pyrolysis combustion flow calorimetry of the composites and each component separately treated with FRs have been conducted and the results analysed in terms of the effect on each component so as to observe any interaction between the different components. The results indicated that in flax/PLA composites, the water released during FR catalysed dehydration-decomposition of flax may hydrolyse PLA, changing decomposition pathway of PLA to produce less flammable volatile, hence resulting in reduced flammability.

Flame Retardancy of High-Density Polyethylene Composites with P,N-Doped Cellulose Fibrils

To derive P,N-doped cellulose fibrils, phosphoric acid and aqueous ammonia were placed in a one-pot reaction, and the phosphate groups and ammonium phosphates were successfully introduced into the cellulose surface. The obtained P,N-doped cellulose fibrils with high liberation were thereafter incorporated into a high-density polyethylene (HDPE) matrix to improve the flame retardancy of HDPE composites, and they had a significant improvement on flame retardancy of HDPE composites. In particular, 7 wt % P,N-doped cellulose fibrils considerably reduced the average and peak heat release rate (HRR) by 29.6% and 72.9%, respectively, and increased the limited oxygen index (LOI) by 30.5%. The presence of phosphate groups and ammonium phosphates within P,N-doped cellulose fibrils was found to promote the thermal degradation of HDPE composites at a lower temperature (i.e., 240 °C). The released acid catalyzed the dehydration of cellulose to form an aromatic carbonaceous structure with a higher crystalline orientation, which improves the flame retardancy of HDPE composites.

Synergistic Effects of Flame Retardants on the Flammability and Foamability of PS Foams Prepared by Supercritical Carbon Dioxide Foaming

Halogen-free flame-retardant polystyrene (PS) foams prepared by supercritical carbon dioxide (SC-CO₂) foaming have been achieved. The flame-retardants include expandable graphite (EG) and melamine phosphate (MP), and their influence on the foamability, decomposition behavior, fire performance, and mechanical properties of PS foams were investigated. It has been shown that flame retardants can generate inert gases and catalyze the char formation from PS, and the formed thick char layer with a notable barrier property can greatly decrease the heat release of PS foams. The addition of triphenyl phosphate (TPP) or hexaphenoxycyclotriphosphazene (HPCTP), which acts as a flame-retardant plasticizer, can obviously improve the foamability and fire performance of the foams. TPP or HPCTP can generate active phosphorous species and phenoxyl radicals to enhance the gas phase flame-retardant effect; therefore, the flame-retarded PS foams (with 25 wt % MP/EG) achieve HF1 and V-0 ratings, with limiting oxygen index (LOI) values of 30.1 or 29.6%, respectively. The numerical assessment of synergistic effects of TPP and HPCTP on further enhancing flame retardancy of PS foams has been provided by the microcalorimeter (MCC) test. Further X-ray photoelectron spectroscopy (XPS) investigation on char residues of PS foams demonstrates the formation of the P-O-C and other stable structures.

Natural Keratin and Coconut Fibres from Industrial Wastes in Flame Retarded Thermoplastic Starch Biocomposites

Natural keratin fibres derived from Mexican tannery waste and coconut fibres from coconut processing waste were used as fillers in commercially available, biodegradable thermoplastic starch-polyester blend to obtain sustainable biocomposites. The morphology, rheological and mechanical properties as well as pyrolysis, flammability and forced flaming combustion behaviour of those biocomposites were investigated. In order to open up new application areas for these kinds of biocomposites, ammonium polyphosphate (APP) was added as a flame retardant. Extensive flammability and cone calorimeter studies revealed a good flame retardance effect with natural fibres alone and improved effectiveness with the addition of APP. In fact, it was shown that replacing 20 of 30 wt. % of APP with keratin fibres achieved the same effectiveness. In the case of coconut fibres, a synergistic effect led to an even lower heat release rate and total heat evolved due to reinforced char residue. This was confirmed via scanning electron microscopy of the char structure. All in all, these results constitute a good approach towards sustainable and biodegradable fibre reinforced biocomposites with improved flame retardant properties.

Polylactic acid biocomposites: approaches to a completely green flame retarded polymer

Basic paths towards fully green flame retarded kenaf fiber reinforced polylactic acid (K-PLA) biocomposites are compared. Multicomponent flame retardant systems are investigated using an amount of 20 wt% such as Mg(OH)2 (MH), ammonium polyphosphate (APP) and expandable graphite (EG), and combinations with silicon dioxide or layered silicate (LS) nanofillers. Adding kenaf fibers and flame retardants increases the E modulus up to a factor 2, although no compatibilizer was used at all. Thus, in particular adding EG and MH decreases the strength at maximum elongation, and kenaf fibers, MH, and EG are crucial for reducing the elongation to break. The oxygen index is improved by up to 33 vol% compared to 17 vol% for K-PLA. The HB classification of K-PLA in the UL 94 test is outperformed. All flame retarded biocomposites show somewhat lower thermal stability and increased amounts of residue. MH decreases the fire load significantly, and the greatest reduction in peak heat release rate is obtained for K-PLA/15MH/5LS. Synergistic effects are observed between EG and APP (ratio 2:1) in flammability and fire properties. Synergistic multicomponent systems containing EG and APP, or MH with adjuvants offer a promising route to green flame retarded natural fiber reinforced PLA biocomposites.

Thermal Measurements on Polymeric Epoxy-Expandable Graphite Material

Combustion measurements, such as heat release rate, critical flux, time-to-ignition, ignition temperature, thermal inertia, and kinematics—activation energy as well as preexponential factor—on epoxy polymer (Prime™20LV) with expandable graphite (EG) inorganic filler of different weight percentage composites, are conducted using the Dual Cone Calorimeter, the thermogravimetric analysis (TGA), and Linseis (Germany) THB100 Transient Hot Bridge thermal conductivity analyser. The results indicate that increasing the amount of EG in polymer composite leads to reduction in the critical flux, the time-to-ignition, the ignition temperature, the thermal inertia, the average thermal conductivity, and the activation energy (from 159.1 ± 2.3 to 145.9 ± 3.1 kJ/mol for neat epoxy to 3 wt.% EG-epoxy) of the composite samples. There is, however, an increase in the heat of gasification with increasing EG content.

Improvement of the flame retardancy of wood-fibre/polypropylene composites with ideal mechanical properties by a novel intumescent flame retardant system

To improve the flame retardancy and maintain the ideal mechanical properties of the widely used wood fibre reinforced polypropylene composite, a novel intumescent flame retardant system consisting of PTPA and APP was developed.

Preparation, thermal stability and flame-retardant properties of halogen-free polypropylene composites

A flame retardant containing phosphorus and nitrogen was prepared. This halogen-free flame retardant was blended with polypropylene (PP) by hot melting to improve the flame-retardant capability and thermal stability of the composites. Fourier transform infrared spectroscopy, energy dispersive X-ray measurements, thermogravimetric analysis, limiting oxygen index (LOI) measurements, and UL-94 measurements were applied to characterize the structure and thermal and flame-retardant properties of the composites. When the flame-retardant concentration was 40 wt%, the LOI value of the composite was 40, passing the V-0 rating of the UL-94 test. The LOI and UL-94 data showed the composites have an excellent flame-retardant property. For a kinetic study of thermal degradation, Ozawa’s method was applied to calculate the activation energies of pure PP and the composites. Analytical results indicate that the composites had higher values, meaning they have better thermal stability.

TG-MS investigation of brominated products from the degradation of brominated flame retardants in high-impact polystyrene

The thermal degradation of flame retardant containing high-impact polystyrene (HIPS-Br), one of the most commonly employed plastics in electric and electronic appliances, was examined by thermogravimetry coupled with mass spectroscopy (TG-MS) in order to understand the threat that is posed by the release of hazardous brominated compounds. The HIPS samples contained decabromodiphenylether (DPE) and decabromodibenzyl (DDB) as the flame retardants as well as Sb2O3 as the synergist. The largest number of brominated compounds was obtained in the presence of DPE and Sb2O3 and DDB without Sb2O3. From the degradation of DPE, brominated benzenes, phenols, diphenylethers, and dibenzofurans were identified, and from the degradation of DDB, brominated benzenes, dibenzyls, and phenanthrenes were formed. The interaction between the flame retardant and the polymer matrix resulted in α-bromoethylbenzene. The formation of brominated dibenzodioxins was not observed, probably, due to the low phenol concentration in the polymer melt. No other report has, to our knowledge, ever reported on the formation of brominated phenanthrenes from flame retardants. Because they share similar steric features, it may well be that brominated phenanthrenes are similar in their carcinogen and mutagen potential to dibenzofurans and dibenzodioxins. A plausible mechanism for the formation of the observed compounds is presented, and the role of the synergist is considered.

Substituição de amianto por silicato de alumínio e grafite expansível em compósito de poliuretano utilizado em motor-foguete

Compósitos de poliuretano e amianto (liner) são utilizados como revestimento interno em paredes de motor-foguete, conferindo proteção térmica e garantindo a adesão entre o propelente e as paredes do motor. No entanto, o uso do amianto tem sido restringido devido à sua toxidade. No presente trabalho, o amianto foi substituído por um silicato de alumínio hidratado (SA) e pelo grafite expansível (GE) em diferentes teores no liner. Resultados de análise termogravimétrica (TG) mostraram que a estabilidade térmica do liner praticamente não é afetada pela substituição das cargas, embora a energia de ativação (Ea) obtida para a decomposição tenha mudado, mostrando maiores valores para as amostras contendo as cargas SA e GE. A análise termomecânica (TMA) mostrou que o coeficiente de expansão térmica linear do liner contendo SA foi menor que aquele encontrado para o liner contendo amianto. O liner contendo a carga SA também apresentou os maiores valores de tensão nos testes mecânicos de tração.

A new method using a health index (HI) to screen low level toxic organic substances in consumer products

To ensure selection of appropriate materials for industrial use in terms of toxicity, a procedure to estimate a health index (HI) that can be used for prioritizing less hazardous components of consumer products is described. The HI is based on the occupational exposure limits (OELs) of organic substances that compose the products. To calculate the HI of a product, it is often necessary to predict OEL values for the substances for which an OEL value has not yet been promulgated. We developed a method to estimate the OEL values from median lethal dose (LD50) data of rodent. A good correlation between known OEL values and the LD50 data was obtained by a multivariate regression analysis by introducing organic compensation coefficients, which were caluculated as 10 to the Bth power where B is the regression coefficient of dummy variables denoting the characteristics of the organic compounds such as functional groups, molecular structures, and so on. We believe that the use of the present method should be limited to predicting unknown OEL values for the HI and used for material prioritization. It should not be extended to determinations of regulatory OELs.