Synthesis of Boron-Containing Toughening Agents and Their Application in Phenolic Foams

Reactive Flame-Retardant Cotton Fabric Coating: Combustion Behavior, Durability, and Enhanced Retardant Mechanism with Ion Transfer

In recent years, we have witnessed numerous indoor fires caused by the flammable properties of cotton. Flame-retardant cotton deserves our attention. A novel boric acid and diethylenetriaminepenta (methylene-phosphonic acid) (DTPMPA) ammonium salt-based chelating coordination flame retardant (BDA) was successfully prepared for cotton fabrics, and a related retardant mechanism with ion transfer was investigated. BDA can form a stable chemical and coordination bond on the surface of cotton fibers by a simple three-curing finishing process. The limiting oxygen index (LOI) value of BDA-90 increased to 36.1%, and the LOI value of cotton fabric became 30.3% after 50 laundering cycles (LCs) and exhibited excellent durable flame retardancy. Fourier-transform infrared (FTIR) spectroscopy, X-ray photoelectron spectroscopy (XPS), and scanning electron microscopy (SEM) methods were used to observe the bonding mode and morphology of BDA on cotton fibers. A synergistic flame-retardant mechanism of condensed and gas phases was concluded from thermogravimetry (TG), cone calorimeter tests, and TG-FTIR. The test results of whiteness and tensile strength showed that the physical properties of BDA-treated cotton fabric were well maintained.

Fire Resistance, Thermal and Anti-Ageing Properties of Transparent Fire-Retardant Coatings Modified with Different Molecular Weights of Polyethylene Glycol Borate

Four kinds of polyethylene glycol borate (PEG-BA) with different molecular weights were grafted into cyclic phosphate ester (PEA) to obtain flexible phosphate esters (PPBs), and then applied in amino resin to obtain a series of transparent intumescent fire-retardant coatings. The comprehensive properties of the transparent coatings containing different molecular weights of PEG-BA were investigated by various analytical instruments. The transparency and mechanical analyses indicate that the presence of PEG-BA slightly decreases the optical transparency of the coatings but improves the flexibility and adhesion classification of the coatings. The results from fire protection and cone calorimeter tests show that low molecular weight of PEG-BA exerts a positive flame-retarded effect in the coatings, while high molecular weight of PEG800-BA behaves against flame-retarded effect. Thermogravimetric and char residue analyses show that the incorporation of low molecular weight of PEG-BA clearly increases the thermal stability and residual weight of the coatings and generates a more compact and stable intumescent char on the surface of the coatings, thus resulting in superior synergistic flame-retarded effect. In particular, MPPB1 coating containing PEG200-BA exerts the best flame-retarded effect and highest residual weight of 36.3% at 700 °C, which has 57.6% reduction in flame spread rate and 23.9% reduction in total heat release compared to those of MPPB0 without PEG-BA. Accelerated ageing test shows that low molecular weight of PEG-BA promotes to enhance the durability of structural stability and fire resistance of the coatings, while PEG800-BA with high molecular weight weakens the ageing resistance. In summary, the fire-resistant and anti-ageing efficiencies of PEG-BA in the coatings depend on its molecular weight, which present the order of PEG200-BA > PEG400-BA > PEG600-BA > PEG800-BA.

Phenolic Resin Foam Composites Reinforced by Acetylated Poplar Fiber with High Mechanical Properties, Low Pulverization Ratio, and Good Thermal Insulation and Flame Retardant Performance

Phenolic foam composites (PFs) are of substantial interest due to their uniform closed-cell structure, low thermal conductivity, and good thermal insulation performance. However, their disadvantages of a high pulverization rate and poor mechanical properties restrict their application in building exterior insulation. Therefore, the toughening of these composites is necessary. In this paper, poplar fiber was treated with an acetylation reagent, and the acetylated fiber was used to prepare modified phenolic foams (FTPFs); this successfully solved the phenomenon of the destruction of the foam structure due to the agglomeration of poplar fiber in the resin substrate. The foam composites were comprehensively evaluated via the characterization of their chemical structures, surface morphologies, mechanical properties, thermal conductivities, and flame retardant properties. It was found that the compressive strength and compressive modulus of FTPF-5% respectively increased by 28.5% and 37.9% as compared with those of PF. The pulverization ratio was reduced by 32.3%, and the thermal insulation performance and flame retardant performance (LOI) were improved. Compared with other toughening methods for phenolic foam composites, the phenolic foam composites modified with surface-compatibilized poplar fiber offer a novel strategy for the value-added utilization of woody fiber, and improve the toughness and industrial viability of phenolic foam.

Preparation and Characterization of Phenolic Foam Modified with Bio-Oil

Bio-oil was added as a substitute for phenol for the preparation of a foaming phenolic resin (PR), which aimed to reduce the brittleness and pulverization of phenolic foam (PF). The components of bio-oil, the chemical structure of bio-oil phenolic resin (BPR), and the mechanical performances, and the morphological and thermal properties of bio-oil phenolic foam (BPF) were investigated. The bio-oil contained a number of phenols and abundant substances with long-chain alkanes. The peaks of OH groups, CH₂ groups, C=O groups, and aromatic skeletal vibration on the Fourier transform infrared (FT-IR) spectrum became wider and sharper after adding bio-oil. These suggested that the bio-oil could partially replace phenol to prepare resin and had great potential for toughening resin. When the substitute rate of bio-oil to phenol (B/P substitute rate) was between 10% and 20%, the cell sizes of BPFs were smaller and more uniform than those of PF. The compressive strength and flexural strength of BPFs with a 10⁻20% B/P substitute rate increased by 10.5⁻47.4% and 25.0⁻50.5% respectively, and their pulverization ratios decreased by 14.5⁻38.6% in comparison to PF. All BPFs maintained good flame-retardant properties, thermal stability, and thermal isolation, although the limited oxygen index (LOI) and residual masses by thermogravimetric (TG) analysis of BPFs were lower and the thermal conducticity was slightly greater than those of PF. This indicated that the bio-oil could be used as a renewable toughening agent for PF.

Fabrication of short glass fiber reinforced phenol-formaldehyde-lignin and polyurethane-based composite foam: mechanical, friability, and shape memory studies

In this research effort, phenol-formaldehyde-lignin (PFL) resin was prepared using phenol, formaldehyde, and lignin via a simple approach. The PFL-polyurethane (PFL-PU) was prepared using PU prepolymer and PFL resin. The blend components were then foamed via addition of Tween 80 surfactant and n-pentane as the blowing agent. Short glass fiber was reinforced in the blend sample to attain high performance composite foams. The composite foams were characterized for structure, morphology, stress-strain behavior, friability tests, and shape memory characteristics. Scanning electron microscopy showed a layered, porous, and distorted hexagonal shaped foam structure. The cell size ranges from 10 to 20 μm for PFL-PU-short glass fiber (SGF) Foam with 10–20 wt.% fiber loading. PFL-PU Foam had compression strength and strain of 48.3 MPa and 48.2%. The PFL-PU-SGF 1–20 Foam showed increase in strength from 55.1 to 101.7 MPa and decrease in strain from 57.8% to 35.8% due to filler addition. At temperature above Tg (130°C), the strain was increased up to 45.11%. The shape fixity was improved up to the addition of 10 wt.% filler where the value of 92.1% was achieved with shape recovery of 95%.