Effect of Nickel-Containing Layered Double Hydroxides and Cyclophosphazene Compound on the Thermal Stability and Flame Retardancy of Poly(lactic acid)

Recent Advances and Outlook in 2D Nanomaterial-Based Flame-Retardant PLA Materials

Poly (lactic acid) or polylactide (PLA) has gained widespread use in many industries and has become a commodity polymer. Its potential as a perfect replacement for petrochemically made plastics has been constrained by its extreme flammability and propensity to flow in a fire. Traditional flame-retardants (FRs), such as organo-halogen chemicals, can be added to PLA without significantly affecting the material's mechanical properties. However, the restricted usage of these substances causes them to bioaccumulate and endanger plants and animals. Research on PLA flame-retardants has mostly concentrated on organic and inorganic substances for the past few years. Meanwhile, there has been a significant increase in renewed interest in creating environmentally acceptable flame-retardants for PLA to maintain the integrity of the polymer, which is the current trend. This article reviews recent advancements in novel FRs for PLA. The emphasis is on two-dimensional (2D) nanosystems and the composites made from them that have been used to develop PLA nanocomposite (NCP) systems that are flame retarding. The association between FR loadings and efficiency for different FR-PLA systems is also briefly discussed in the paper, as well as their influence on processing and other material attributes. It is unmistakably established from the literature that adding 2D nanoparticles to PLA matrix systems reduces their flammability by forming an intumescent char/carbonized surface layer. This creates a barrier effect that successfully blocks the filtration of volatiles and oxygen, heat and mass transfer, and the release of combustible gases produced during combustion.

Halogen-free layered double hydroxide-cyclotriphosphazene carboxylate flame retardants: effects of cyclotriphosphazene di, tetra and hexacarboxylate intercalation on layered double hydroxides against the combustible epoxy resin coated on wood substrates

The development of halogen-free flame retardants as environmentally friendly and renewable materials for heat and fire-resistant applications in the field of electronics is important to ensure safety measures. In this regard, we have proposed a simple and halogen-free strategy for the synthesis of flame retardant LDH-PN materials to decrease the fire hazards of epoxy resin (EP), via a co-precipitation reaction between Mg(NO3)2 and Al(NO3)3 and the subsequent incorporation of different cyclotriphosphazene (PN) carboxylate anions. The cyclotriphosphazene-based di, tetra and hexacarboxylate-intercalated layered double hydroxides are designated as LDH-PN-DC, LDH-PN-TC and LDH-PN-HC, respectively. Furthermore, the intercalation of cyclotriphosphazene carboxylate anions into the LDH layers was confirmed by PXRD, FT-IR, TGA, solid-state 31P NMR, nitrogen adsorption and desorption analysis (BET), HR-SEM and XPS. Evaluation of the flame retardant (vertical burning test and limiting oxygen index) properties was demonstrated by formulating the LDH-PN materials with epoxy resin (EP) in different ratios coated on wood substrates to achieve the desired behaviour of the EP/LDH-PN composites. Structure-property analysis reveals that EP/LDH-PN-TC-20 wt% and EP/LDH-PN-HC-20 wt% achieved a V 0 rating in the UL-94 V test and achieved higher LOI values (27.7 vol% for EP/LDH-PN-TC-20 wt% and 29 vol% for EP/LDH-PN-HC-20 wt%) compared to the epoxy-coated wood substrate (23.2 vol%), whereas EP/LDH-PN-DC failed in the vertical burning test for various weight percentages of LDH-PN-DC from 5 wt% to 20 wt% in the composites, with a lower LOI value of 22.1 vol%. Excellent flame retardancy was observed for EP/LDH-PN-TC and EP/LDH-PN-HC due to the presence of more binding sites of carboxylate anions in the LDH layers and less or no spiro groups in cyclotriphosphazene compared to that in EP/LDH-PN-DC. In addition, the synergistic flame retardant effect of the combination of LDH and cyclotriphosphazene on the epoxy resin composites remains very effective in creating a non-volatile protective film on the surface of the wood substrate to shelter it from air, absorb the heat and increase the ignition time, which prevents the supply of oxygen during the combustion process. The results of this study show that the proposed strategy for designing flame-retardant properties represents the state-of-the-art, competent coating of inorganic materials for the protection and functionalization of wood substrates.

Synergistic Effect of Multifunctional Layered Double Hydroxide-Based Hybrids and Modified Phosphagen with an Active Amino Group for Enhancing the Smoke Suppression and Flame Retardancy of Epoxy

To improve the fire hazard of epoxy resin (EP), phosphomolybdate (PMoA), as a classical Keggin cluster, was successfully intercalated into Mg, Al, and Zn layered double hydrotalcite (LDH) by the reconstruction method, and it was denoted as MgAlZn-LDH-PMoA. The structure and morphology of MgAlZn-LDH-PMoA were characterized by X-ray diffraction and Fourier transform infrared spectroscopy. Subsequently, hexa(4-aminophenoxy)cyclotriphosphazene (HACP) was prepared and characterized as a high-performance organic flame retardant, which is rich in flame elements phosphorus and nitrogen. The synergistic effects of MgAlZn-LDH-PMoA and HACP on the fire safety of EP composites loaded with different amounts of flame retardant hybrids were studied in detail. Thermogravimetric analysis showed that the char residue of these EP composites increased significantly. Compared with the EP matrix filled with only MgAlZn-LDH-PMoA or HACP, the incorporation of MgAlZn-LDH-PMoA and HACP had a synergistic effect on promoting char formation of EP composites. Particularly, the char yield of EP7 is as high as 29.0%. Furthermore, the synergistic effects of incorporation of MgAlZn-LDH-PMoA with HACP were investigated using the cone calorimeter combustion tests. The results showed that the total heat release and peak heat release rate of the EP composites remarkably declined by 35.2 and 50.9%, respectively, with a loading of 7 wt % hybrid flame retardant. Moreover, the hybrid flame retardants also showed an obvious inhibitory effect on the total smoke production and the release of toxic CO gas. The detailed analysis of the residual char indicated that the main mechanism for improving the flame retardancy and smoke suppression performance is due to both the catalytic carbonization of MgAlZn-LDH-PMoA and phosphoric acid compounds and physical barrier function of the char layer. In addition, the molybdenum oxides produced from [PMo₁₂O₄₀]^3- during combustion can not only increase the yield and compactness of the char layer but also reduce the release of CO through a redox reaction, which has important application value to reduce the fire hazard.

Ammonium Polyphosphate Intercalated Yttrium-Doped Layered Double Hydroxides to Enhance the Thermal Stability and Flame Retardancy of Poly(Lactic Acid)

The flammability of the biodegradable plastic PLA limits its application in industrial fields with high flame-retardant requirements. This paper provides a novel strategy for constructing refractory and thermostable PLA composites using layered double hydroxides (LDHs) chemically modified with ammonium polyphosphate (APP). XRD, FT-IR, SEM-EDS, and TEM confirm that the goal of LDHs has been successfully prepared. The thermal stability and combustion behavior of PLA composites were evaluated by the thermogravimetric analysis (TGA) and cone calorimetry tests (CCT). The crystallization behavior and tensile performances were also examined. The results showed that the incorporation of 15 wt% MgAlY-APP-LDHs practically makes the PLA composites reach the UL-94 V-0 grade. There were 43% and 20% reduction in the PHRR and THR of PLA/15APP-LDHs respectively due to the catalytic effect of Y elements and barrier effects of LDHs, which was a major performance against fire hazards. Furthermore, the increase in crystallinity and the decrease in mechanical strength of PLA composites are attributed to the nucleation of LDHs. In short, this research introduces the production of multifunctional PLA composites through APP intercalation of LDHs, which are deemed as prospective candidates for the next generation of sustainable plastics products.

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.

UV absorber co-intercalated layered double hydroxides as efficient hybrid UV-shielding materials for polypropylene

UV absorber co-intercalated layered double hydroxides can efficiently shield UV light and greatly enhance the anti-photoaging performance of polypropylene.

The synergistic effect of layered double hydroxides with other flame retardant additives for polymer nanocomposites: a critical review

Layered double hydroxides (LDHs) are a new type of inorganic flame retardant additive for polymer nanocomposites. Although their unique structural properties and tunable chemical compositions make them highly promising, it has been noticed that on their own, LDHs can hardly fulfill all the requirements for commercial applications. In recent years, the application of LDHs together with other synergistic additives has been proposed as a new route for obtaining highly efficient flame retardant polymer nanocomposites. It is believed that the synergistic additives can overcome the shortcomings of LDHs. As great progress has been made in this field so far, we believe that a timely review is warranted. Thus, in this contribution, the synergistic effect of LDHs with other flame retardant additives including (1) phosphorus-containing compounds, (2) graphene and carbon compounds, (3) intumescent flame retardants, (4) magnesium hydroxide, (5) borate-containing compounds, and (6) some other flame retardant compounds will be critically reviewed. For each type of additive, the synergistic mechanism with LDHs, and their performance on both flame retardancy and thermal stability will be discussed. We believe that this work will inspire and guide researchers from a wide range of backgrounds and help to pave the way for major breakthroughs in both fundamental studies and industrial applications in this field.

Advances in Flame Retardant Poly(Lactic Acid)

PLA has become a commodity polymer with wide applications in a number of fields. However, its high flammability with the tendency to flow in fire has limited its viability as a perfect replacement for the petrochemically-engineered plastics. Traditional flame retardants, which may be incorporated into PLA without severely degrading the mechanical properties, are the organo-halogen compounds. Meanwhile, these compounds tend to bioaccumulate and pose a risk to flora and fauna due to their restricted use. Research into PLA flame retardants has largely focused on organic and inorganic compounds for the past few years. Meanwhile, the renewed interest in the development of environmentally sustainable flame retardants (FRs) for PLA has increased significantly in a bid to maintain the integrity of the polymer. A review on the development of new flame retardants for PLA is presented herein. The focus is on metal oxides, phosphorus-based systems, 2D and 1D nanomaterials, hyperbranched polymers, and their combinations, which have been applied for flame retarding PLA are discussed. The paper also reviews briefly the correlation between FR loadings and efficiency for various FR systems, and their effects on processing and mechanical properties.

Construction of Bimetallic ZIF-Derived Co-Ni LDHs on the Surfaces of GO or CNTs with a Recyclable Method: Toward Reduced Toxicity of Gaseous Thermal Decomposition Products of Unsaturated Polyester Resin

This work proposed an idea of recycling in preparing Co-Ni layered double hydroxide (LDH)-derived flame retardants. A novel and feasible method was developed to synthesize CO-Ni LDH-decorated graphene oxide (GO) and carbon nanotubes (CNTs), by sacrificing bimetal zeolitic imidazolate frameworks (ZIFs). Organic ligands that departed from ZIFs were recyclable and can be reused to synthesize ZIFs. ZIFs, as transitional objects, in situ synthesized on the surfaces of GO or CNTs directly suppressed the re-stacking of the carbides and facilitated the preparation of GO@LDHs and CNTs@LDHs. As-prepared hybrids catalytically reduced toxic CO yield during the thermal decomposition of unsaturated polyester resin (UPR). What is more, the release behaviors of aromatic compounds were also suppressed during the pyrolysis process of UPR composites. The addition of GO@LDHs and CNTs@LDHs obviously inhibited the heat release and smoke emission behaviors of the UPR matrix during combustion. Mechanical properties of the UPR matrix also improved by inclusion of the carbides derivatives. This work paved a feasible method to prepare well-dispersed carbides@Co-Ni LDH nanocomposites with a more environmentally friendly method.

The flame retardancy and smoke suppression effect of a hybrid containing CuMoO4 modified reduced graphene oxide/layered double hydroxide on epoxy resin

The co-precipitation method was used to synthesize a hybrid with MgAl-layered double hydroxide loaded graphene (RGO-LDH). CuMoO₄ was then introduced onto the surface of RGO-LDH to prepare a hybrid with CuMoO₄ modified RGO-LDH (RGO-LDH/CuMoO₄). The composition, structure and morphology of RGO-LDH/CuMoO₄ were characterized by X-ray diffraction, Laser raman spectroscopy and Transmission electron microscope-energy-dispersive X-ray spectroscopy. It was found that the hybrid of RGO-LDH/CuMoO₄ had been successfully prepared. The effects of flame retardancy and smoke suppression of epoxy resin were studied with added RGO-LDH/CuMoO₄. Results showed that the PHRR and THR of the EP composite with RGO-LDH/CuMoO₄ added were decreased dramatically. The char yield, LOI and UL-94 vertical burning rating of the EP composite were increased, with improved flame ratardancy. In addition, the SPR, TSP, and D_s,max of the EP composite were decreased drastically with added RGO-LDH/CuMoO₄. Its improved flame retardancy and smoke suppression performance were due mainly to the physical barrier of graphene and LDH, and the catalytic carbonization function of LDH. Meanwhile, Cu₂O and MoO₃ generated from RGO-LDH/CuMoO₄ in the combustion process helped enhance the production of char residue and raised the compactness of the char layer.

Synthesis of a novel polyphosphate and its application with APP in flame retardant PLA

A phosphorus-containing flame retardant was synthesized via an A₂ + B₃ type reaction of bisphenolic acid-based monomer and phosphorus oxychloride. Then, intumescent flame retardant systems were prepared by combining PFRS with ammonium polyphosphate.

The effect of chitosan on the flammability and thermal stability of polylactic acid/ammonium polyphosphate biocomposites

This work reports our recent efforts on introducing chitosan (CS) in association with ammonium polyphosphate (APP) into polylactic acid (PLA) by melt blending to improve the flame retardancy of the biocomposites. The flammability of the composites was characterized by limiting oxygen index (LOI), UL-94 vertical burning test and cone calorimetry test (CONE). The results showed that the PLA sample containing 2% CS and 5% APP achieved the maximal LOI value of 33.1, passed the UL-94 V-0 rating, and decreased the peak heat release rate to 425.6kW/m². The morphology characterization of char residue by scanning electron microscope indicated a dense, homogeneous and continuous residue char could be formed by the presence of APP and CS in PLA. Fourier transform infrared spectroscopy and thermal gravity analysis suggested that CS could act as a novel carbon agent owning to its high content of carbon atoms and multi-hydroxyl groups, and the interaction between CS and APP could provide synergistic effects in improving the flame retardancy of PLA biocomposites. X-ray diffraction and differential scanning calorimetry results demonstrated that the presence of APP and CS could promote the crystallization of PLA.

Synergistic flame retardant properties of a layered double hydroxide in combination with zirconium phosphonate in polypropylene

High-performance flame retardant nanocomposites were prepared for polypropylene (PP).

PGS@B–N: an efficient flame retardant to improve simultaneously the interfacial interaction and the flame retardancy of EVA

EVA/PGS@B–N composites with suitable loadings of PGS@B–N particles have significantly improved flame retardancy.

Synthesis of aminopropyltriethoxysilane grafted/tripolyphosphate intercalated ZnAl LDHs and their performance in the flame retardancy and smoke suppression of polyurethane elastomer

Synthesis procedure of APTS grafted/P₃O₁₀⁵⁻ intercalated LDHs.