Flame Retardant Epoxy Composites on the Road of Innovation: An Analysis with Flame Retardancy Index for Future Development

Flame retardancy and smoke suppression properties of bio-based chitosan polyelectrolyte flame retardant containing P and N in epoxy resin

This study reports the successful synthesis of flame-retardant and smoke-suppressing epoxy resin (EP) via bio-based polyelectrolyte flame retardants. Herein, a novel polyelectrolyte flame retardant was prepared from chitosan (CS) and hexa-(4-carboxyl-phenoxy)-cyclotriphosphazene (HCPCP) by acid-base neutralization reaction, which the HCPCP was synthesized with hexachlorocyclotriphosphazene (HCCP) and methyl p-hydroxybenzoate (MP) by nucleophilic substitution reaction. The combined effect of the addition on the flame retardant, smoke suppression and mechanical properties of EP samples were systematically investigated. The presence of this bio-based polyelectrolyte provided excellent smoke suppression and flame-retardant properties of the prepared EP. Among them, the peak heat release rate (PHRR), peak smoke production rate (PSPR) and total smoke production (TSP) of EP/9wt%3CS-HCPCP composite (the ratio of CS to HCPCP was 3: 7, and the dosage was 9 wt%) were reduced by 45.42 %, 41.66 % and 22.56 %, respectively. In addition, the EP/CS-HCPCP composites showed a 207.80 % enhancement in char residue compared to pure EP. These results suggest a green and cost-effective strategy for the production of flame-retardant, drip-proof and smoke-suppressed EP composites.

Green Flame-Retardant Blend Used to Improve the Antiflame Properties of Polypropylene

The flammability properties of polymers and polymeric composites play an important role in ensuring the safety of humans and the environment; moreover, flame-retardant materials ensure a greater number of applications. In the present study, we report the obtaining of polypropylene (PP) composites contain a mixture of two green flame retardants, lignin and clinoptilolite, by melt extrusion. These additives are abundantly found in nature. Fourier transform infrared (FT-IR), thermogravimetric analysis (TGA), mechanical properties, scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDS), cone calorimetry, UL-94, and carbonized residues analysis were carried out. TGA analysis shows that PPGFR-10 and PPGFR-20 compounds presented better thermal stability with respect to PP without flame retardants. The conical calorimetric evaluation of the composites showed that PPGFR-10 and PPGFR-20 presented decreases in peak heat release rates (HRRs) of 9.75% and 11.88%, respectively. The flammability of the composites was evaluated with the UL-94 standard, and only the PPGFR-20 composite presented the V-0 and 5VB classification, which indicates good flame-retardant properties. Additives in the polymer matrix showed good dispersion with few agglomerates. The PPGFR-20 composite showed an FRI value of 1.15, higher percentage of carbonized residues, and UL-94 V-0 and 5VB rating, suggesting some kind of synergy between lignin and clinoptilolite, but only at high flame-retardant concentrations.

Fire-Retardant Flexible Foamed Polyurethane (PU)-Based Composites: Armed and Charmed Ground Tire Rubber (GTR) Particles

Inadequate fire resistance of polymers raises questions about their advanced applications. Flexible polyurethane (PU) foams have myriad applications but inherently suffer from very high flammability. Because of the dependency of the ultimate properties (mechanical and damping performance) of PU foams on their cellular structure, reinforcement of PU with additives brings about further concerns. Though they are highly flammable and known for their environmental consequences, rubber wastes are desired from a circularity standpoint, which can also improve the mechanical properties of PU foams. In this work, melamine cyanurate (MC), melamine polyphosphate (MPP), and ammonium polyphosphate (APP) are used as well-known flame retardants (FRs) to develop highly fire-retardant ground tire rubber (GTR) particles for flexible PU foams. Analysis of the burning behavior of the resulting PU/GTR composites revealed that the armed GTR particles endowed PU with reduced flammability expressed by over 30% increase in limiting oxygen index, 50% drop in peak heat release rate, as well as reduced smoke generation. The Flame Retardancy Index (FRI) was used to classify and label PU/GTR composites such that the amount of GTR was found to be more important than that of FR type. The wide range of FRI (0.94-7.56), taking Poor to Good performance labels, was indicative of the sensitivity of flame retardancy to the hybridization of FR with GTR components, a feature of practicality. The results are promising for fire protection requirements in buildings; however, the flammability reduction was achieved at the expense of mechanical and thermal insulation performance.

Preparation of High-Transparency Phosphenanthrene-Based Flame Retardants and Studies of Their Flame-Retardant Properties

Transparency is an important property for polymer flame retardants, especially epoxy resin (EP) flame retardants, and flame-retardant epoxy resins that maintain a high transparency and low chromatic aberration play important roles in the optical, lighting, and energy industries. Herein, a DOPO-based flame retardant 6,6'-((sulfonylbis(4,1-phenylene))bis(oxy))bis(dibenzo[c,e][1,2]oxaphosphinine 6-oxide) with a high transparency and low chromatic aberration was prepared via the classical Atherton-Todd reaction and named SBPDOPO. Its chemical structure was characterized with Fourier IR spectroscopy and NMR spectroscopy. An EP loaded with 7 wt% SBPDOPO passed the UL-94 V-0 rating with an LOI value of 32.1%, and the peak heat release rate, total heat release, and total smoke production were reduced by 34.1%, 31.6%, and 27.7%, respectively, compared with those of pure EP. In addition, the addition of SBPDOPO improved the thermal stability, residual mass, and glass transition temperature of the EP. On this basis, the EP containing 7 wt% SBPDOPO maintained a high transparency and low color aberration, with a transmittance of 94% relative to that of pure EP and a color aberration ΔE of 1.63. Finally, the flame-retardant mechanism of SBPDOPO was analyzed, which demonstrated that it exerted both gas-phase and condensed-phase flame-retardant effects, and that SBPDOPO/EP had high potential for application scenarios in which both flame retardancy and transparency are needed. SBPDOPO/EP has great potential for applications requiring both flame retardancy and transparency.

Ultra-High-Temperature Ceramic-Doped Inorganic Polymers for Thermo-Structural Fiber-Reinforced Composites

New inorganic nanostructured matrices for fiber-reinforced composites with enhanced high-temperature stability were developed from alkali aluminosilicate polymers doped with different ultra-high-temperature ceramic (UHTC) particles. The alkali aluminosilicate matrices were synthesized at room temperature with a high SiO2:Al2O3 ratio and then further functionalized by doping with 4-5 wt % of micrometric SiC, ZrB2, ZrC, and HfC powders and finally thermally stabilized as glass-ceramics at 750 °C. The different UHTC-doped matrices were characterized according to their dimensional and microstructural changes after thermal cycling in air flux at 1000 °C. The first results showed that carbide-based UHTC powders improved the thermal stability of the matrices, preventing the excessive swelling of the material and the formation of detrimental voids that might result in the lack of adhesion with reinforcing fibers. Contrarily, the addition of ZrB2 resulted in an excessive matrix swelling at high temperature, thus proving no efficacy compared to the undoped matrix. Impregnation tests carried out on C-fiber fabrics showed good processability, adhesion to the fibers, and fracture pull-out, especially for carbide-based matrices.

Analysis of the Impact of Rubber Recyclate Addition to the Matrix on the Strength Properties of Epoxy-Glass Composites

Currently, there is a noticeable trend of modifying new materials by using additives from the recycling of harmful waste. This is to protect the environment by using waste to produce composites and at the same time to reduce the cost of their production. The article presents an analysis of the impact of the use of rubber recyclate obtained from the utilization of car tires as a sandwich layer of epoxy-glass composites and its impact on the strength parameters of the composite. The presented research is an extension of the previously conducted analyses on composite materials modified with the addition of rubber recyclate. The four variants of the materials produced contained the same percentage amount of rubber recyclate, but differed in the way it was distributed and the number of layers. Static tensile tests as well as impact strength and kinetics of damage to samples made with and without the addition of recyclate were carried out. Observation of the structures of the materials with the use of SEM was also performed. A significant influence of the method of distributing the recyclate in layers on the strength parameters of the materials was found. In the case of composites with three and two sandwich layers of recyclate, more favorable results were obtained compared to the blank sample. In addition, the values of the impact strength measurements were subjected to statistical analysis at the significance level of α = 95%. The distributions were tested for normality with the Shapiro-Wilk test, differences between pairs were tested with the Student's t-test for dependent groups, and ANOVA differences were tested for independent groups. Using the Student's t-test, it was confirmed that between the pairs of variables in the configurations reference sample and modified sample, there were significant statistical differences in the distribution of impact strength measurement results for all the analyzed materials. Statistical analysis showed a significant usefulness in the selection of the material with the best strength parameters and a significant role of statistical methods in the study of anisotropic materials.

Flame Retardancy Index (FRI) for Polymer Materials Ranking

In 2019, we introduced Flame Retardancy Index (FRI) as a universal dimensionless index for the classification of flame-retardant polymer materials (Polymers, 2019, 11(3), 407). FRI simply takes the peak of Heat Release Rate (pHRR), Total Heat Release (THR), and Time-To-Ignition (t_i) from cone calorimetry data and quantifies the flame retardancy performance of polymer composites with respect to the blank polymer (the reference sample) on a logarithmic scale, as of Poor (FRI ˂ 10⁰), Good (10⁰ ≤ FRI ˂ 10¹), or Excellent (FRI ≥ 10¹). Although initially applied to categorize thermoplastic composites, the versatility of FRI was later verified upon analyzing several sets of data collected from investigations/reports on thermoset composites. Over four years from the time FRI was introduced, we have adequate proof of FRI reliability for polymer materials ranking in terms of flame retardancy performance. Since the mission of FRI was to roughly classify flame-retardant polymer materials, its simplicity of usage and fast performance quantification were highly valued. Herein, we answered the question "does inclusion of additional cone calorimetry parameters, e.g., the time to pHRR (t_p), affect the predictability of FRI?". In this regard, we defined new variants to evaluate classification capability and variation interval of FRI. We also defined the Flammability Index (FI) based on Pyrolysis Combustion Flow Calorimetry (PCFC) data to invite specialists for analysis of the relationship between the FRI and FI, which may deepen our understanding of the flame retardancy mechanisms of the condensed and gas phases.

Analysis of Selected Organophosphorus Compounds and Nano-Additives on Thermal, Smoke Properties and Quantities of CO and CO2 of Epoxy Materials

Majority of anthropogenic air pollutants enter the atmosphere as a result of material combustion, industrial production and transport. Fires not only cause air pollution, but also disrupt ecosystems. Knowledge of the flammability parameters and proper flame-retardant modification of materials hinders the origin and spread of a fire, while also protecting against air pollution. The aim of this study was to obtain fire-retardant modifications of the epoxy resin, and then to analyse the effect of the introduced additives on the rate of heat release, the thermokinetic properties and the toxicity of volatile combustible products. The modifiers of the epoxy resin were organophosphorus compounds and aluminium and magnesium hydroxides, with a grain size of 10 nm. The introduced additives were found to be effective flame retardants as they reduced the rate of heat release and the amounts of toxic products of thermal decomposition and combustion. The HRR_max and HRR_av values of all fire-retardant modifications were lower compared to the corresponding HRR values of the unmodified epoxy material.

Synthesis of High-Molecular-Weight Bifunctional Additives with both Flame Retardant Properties and Antistatic Properties via ATRP

Polystyrene (PS) is widely used in our daily life, but it is flammable and produces a large number of toxic gases and high-temperature flue gases in the combustion process, which limit its application. Improving the flame retardancy of PS has become an urgent problem to be solved. In addition, in view of the disadvantage that small-molecule flame retardants can easily migrate from polymers during use, which leads to the gradual reduction of the flame retardant effect or even loss of flame retardant performance, and the outstanding advantages of ATRP technology in polymer structure design and function customization, we used ATRP technology to synthesize the high-molecular-weight bifunctional additive PFAA-DOPO-b-PDEAEMA, which has flame retardant properties and antistatic properties. The chemical structure and molecular weight of PFAA-DOPO-b-PDEAEMA were characterized by FTIR, ¹H NMR, GPC, and XPS. When the addition of PFAA-DOPO-b-PDEAEMA was 15 wt %, the limiting oxygen index (LOI) of polystyrene composites was 28.4%, which was 53.51% higher than that of pure polystyrene, the peak of the heat release rate (pHRR) was 37.61% lower than that of pure polystyrene, UL-94 reached V-0 grade, and the flame retardant index (FRI) was 2.98. In addition, when the PFAA-DOPO-b-PDEEMA content is 15 wt %, the surface resistivity and volume resistivity of polystyrene composites are 2 orders of magnitude lower than those of polystyrene. This research work provides a reference for the design of bifunctional and even multifunctional polymers.

Thermal Properties and Flammability Characteristics of a Series of DGEBA-Based Thermosets Loaded with a Novel Bisphenol Containing DOPO and Phenylphosphonate Units

Despite a recent sustained preoccupation for developing biobased epoxies with enhanced applicability, such products have not been widely accepted for industry because of their inferior characteristics compared to classic petroleum-based epoxy thermosets. Therefore, significant effort is being made to improve the flame retardance of the most commonly used epoxies, such as diglycidyl ether-based bisphenol A (DGEBA), bisphenol F (DGEBF), novalac epoxy, and others, while continuously avoiding the use of hazardous halogen-containing flame retardants. Herein, a phosphorus-containing bisphenol, bis(4-(((4-hydroxyphenyl)amino)(6-oxido-6H-dibenzo[c,e][1,2]oxaphosphinin-6-yl)methyl)phenyl) phenylphosphonate (BPH), was synthesized by reacting bis(4-formylphenyl)phenylphosphonate with 4-hydroxybenzaldehyde followed by the addition of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) to the resulting azomethine groups. Environmentally friendly epoxy-based polymer thermosets were prepared by using epoxy resin as polymer matrix and a mixture of BPH and 4,4'-diaminodiphenylsulfone (DDS) as hardeners. A hyperbranched phthalocyanine polymer (HPc) and BaTiO₃ nanoparticles were incorporated into epoxy resin to improve the characteristics of the final products. The structure and morphology of epoxy thermosets were evaluated by infrared spectroscopy and scanning electron microscopy (SEM), while the flammability characteristics were evaluated by microscale combustion calorimetry. Thermal properties were determined by thermogravimetric analysis and differential scanning calorimetry. The surface morphology of the char residues obtained by pyrolysis was studied by SEM analysis.

Effects of Phosphorus and Boron Compounds on Thermal Stability and Flame Retardancy Properties of Epoxy Composites

While plastics are regarded as the most resourceful materials nowadays, ranging from countless utilities including protective or decorating coatings, to adhesives, packaging materials, electronic components, paintings, furniture, insulating composites, foams, building blocks and so on, their critical limitation is their advanced flammability, which in fire incidents can result in dramatic human fatalities and irreversible environmental damage. Herein, epoxy-based composites with improved flame-resistant characteristics have been prepared by incorporating two flame retardant additives into epoxy resin, namely 6-(hydroxy(phenyl)methyl)-6H-dibenzo[c,e][1,2]oxaphosphinine-6-oxide (PFR) and boric acid (H₃BO₃). The additional reaction of 9,10-dihydro-oxa-10-phosphophenanthrene-10-oxide (DOPO) to the carbonyl group of benzaldehyde yielded PFR, which was then used to prepare epoxy composites having a phosphorus content ranging from 1.5 to 4 wt%, while the boron content was 2 wt%. The structure, morphology, thermal stability and flammability of resulted epoxy composites were investigated by FTIR spectroscopy, scanning electron microscopy (SEM), thermogravimetric analysis, differential scanning calorimetry, and microscale combustion calorimetry (MCC). Thermogravimetric analysis indicated that the simultaneous incorporation of PFR and H₃BO₃ improved the thermal stability of the char residue at high temperatures. The surface morphology of the char residues, studied by SEM measurements, showed improved characteristics in the case of the samples containing both phosphorus and boron atoms. The MCC tests revealed a significant reduction in flammability as well as a significant decrease in heat release capacity for samples containing both PFR and H₃BO₃ compared to the neat epoxy thermoset.

Effect of Hygrothermal Ageing on the Mechanical and Fire Properties of a Flame Retardant Flax Fiber/Epoxy Composite

In engineering applications, natural fiber composites must comply with fire requirements including the use of flame retardant. Furthermore, biocomposites are known to be water sensitive. Whether flame retardants affect the water sensitivity and whether water absorption affects the fire behavior and the mechanical performance of biocomposites are the two main topics addressed in this work. In this study, a flax fiber/epoxy composite flame retardant with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) or aluminum diethyl phosphinate (AlPi) was aged in humid atmosphere or by immersion in water. Water absorption kinetics revealed that DOPO induces an increase in equilibrium water content by approximately a factor of 2 due to its intrinsic hygroscopicity and/or its plasticizing effect on the epoxy matrix. In contrast, AlPi does not significantly change the water sensitivity of the biocomposite. Mechanical testing highlighted that, whatever the FR, the evolution of mechanical properties with ageing is governed by the moisture content. The drop of elastic modulus was attributed to a decrease in fiber rigidity due to plasticization, while the increase in tensile strength was assigned to an increase in fiber/matrix friction due to fiber swelling. As regards flame retardancy, only the highest water contents modified the fire behavior. For the AlPi containing biocomposite, the water release resulted in an increase by 50% of the time to ignition, while for the DOPO flame retardant biocomposite the water release was mainly postponed after ignition.

Effect of the Coupling Agent (3-Aminopropyl) Triethoxysilane on the Structure and Fire Behavior of Solvent-Free One-Pot Synthesized Silica-Epoxy Nanocomposites

Uniformly distributed silica/epoxy nanocomposites (2 and 6 wt.% silica content) were obtained through a “solvent-free one-pot” process. The inorganic phases were obtained through “in situ” sol-gel chemistry from two precursors, tetraethyl orthosilicate (TEOS) and (3-aminopropyl)-triethoxysilane (APTES). APTES acts as a coupling agent. Surprisingly when changing TEOS/APTES molar ratio (from 2.32 to 1.25), two opposite trends of glass transformation temperature (Tg) were observed for silica loading, i.e., at lower content, a decreased Tg (for 2 wt.% silica) and at higher content an increased Tg (for 6 wt.% silica) was observed. High-Resolution Transmission Electron Microscopy (HRTEM) showed the formation of multi-sheet silica-based nanoparticles with decreasing size at a lower TEOS/APTES molar ratio. Based on a recently proposed mechanism, the experimental results can be explained by the formation of a co-continuous hybrid network due to reorganization of the epoxy matrix around two different “in situ” sol-gel derived silicatic phases, i.e., micelles formed mainly by APTES and multi-sheet silica nanoparticles. Moreover, the concentration of APTES affected the size distribution of the multi-sheet silica-based nanoparticles, leading to the formation of structures that became smaller at a higher content. Flammability and forced-combustion tests proved that the nanocomposites exhibited excellent fire retardancy.

Synthesis of a highly efficient flame retardant containing triazine and pentaerythritol phosphate groups and its intumescent flame retardancy on epoxy resin

A novel phosphorus-nitrogen-containing flame retardant (DOPT) has been successfully synthesized via the substitution reaction of cyanuric chloride, pentaerythritol phosphate and 9, 10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide. The chemical structure of DOPT was confirmed by 1H, 31P and 13C nuclear magnetic resonance, Fourier transform infrared spectroscopy and elemental analysis. Then, flame retardants were added to epoxy resin to prepare epoxy resin composites by pouring method. Thermal properties, flame retardancy, and combustion behavior of epoxy resin composites were evaluated by thermogravimetric analysis, vertical burning, limiting oxygen index and cone calorimeter test. Thermogravimetric analysis test showed that the carbon residue rate of DOPT at 800°C reached 52.53%, which indicated that the introduction of high-efficiency char-forming agent triazine and pentaerythritol phosphate groups could significantly improve its char-forming performance and thermal stability. The epoxy resin composite achieved vertical burning V-0 grade and the limiting oxygen index value reached 35.5% when 7 wt% DOPT was incorporated. Furthermore, the cone calorimeter test results manifested that the addition of DOPT stimulated degradation of the epoxy resin matrix during the combustion process and accelerated the formation of an expanded and dense carbon layer. Additionally, the incombustible gas produced during the decomposition of DOPT had played a flame-retardant effect in the gas phase. Hence, compared with neat epoxy resin, the total heat release and total smoke production of the EP-7 wt% DOPT composite decreased by 14.0% and 25.3%, respectively. Moreover, owing to the excellent compatibility and the strong interface effect between DOPT and epoxy resin, the addition of DOPT also enhanced the mechanical and fire resistance properties of the epoxy resin composite. Therefore, it is proposed that DOPT could be exploited as an economical and high-efficiency flame retardant, and it has considerable prospects in flame retardant epoxy resin composites.

From herbicide to flame retardant: The lamellar-like phosphorus-bridged amitrole toward high fire safety epoxy resin with light smoke and low toxicity

In an attempt to alleviate the harmful impact of the flammability of epoxy resin on the environment, amitrole, a herbicide, has been converted to a novel flame retardant (PBA) with lamellar morphology through organophosphorus modification. This material has been utilized to fabricate fire safe epoxy thermosets (EP). EP containing 7.5 wt% PBA undergoes quick self-extinguishment upon ignition. This blend displays a high limiting oxygen index (LOI) value of 34%. More importantly, hazardous products (heat, smoke, toxic gases including CO/CO₂) released during combustion of EP, are strongly suppressed in the presence of PBA. The mechanical properties of EP-PBA blends are comparable to those of virgin EP. The tensile strength of EP containing PBA is 90% of that of unmodified EP. The flexural strength of PBA blends is somewhat greater than that for EP containing no additive. A tactful strategy for the transformation of amitrole, a potential environmental contaminant to a benign flame retardant for polymers has been developed.

Experimental and Numerical Study of Downward Flame Spread over Glass-Fiber-Reinforced Epoxy Resin

For the first time, a comprehensive study of downward flame spread over glass-fiber-reinforced epoxy resin (GFRER) slabs in oxidizer flow has been carried out experimentally and numerically. Microthermocouples were used to measure the temperature profiles on the solid fuel’s surface and in the flame, and a video camera was used to measure the rate of flame spread (ROS). The ROS was found to be linearly dependent on the oxygen concentration, to be inversely proportional to the slab thickness and not to depend on the direction of the flame spread over the slab. The absence of the influence of the forced oxidizing flow velocity and the weak influence of the GFRER pyrolysis kinetics on the ROS were observed. For the first time, a numerical model of flame spread over reinforced material with thermal conductivity anisotropy was developed on the basis of a coupled ‘gas–solid’ heat and mass transfer model, using modifications of the OpenFOAM open-source code. The sensitivity analysis of the model showed that the thermal conductivity in the normal direction to the GFRER surface had a much greater effect on the ROS than the thermal conductivity along the direction of flame propagation. The numerical results show good agreement with the experimental data on the dependences of the ROS on oxygen concentration, slab thickness and the N₂/O₂ mixture flow velocity, as well as temperature distributions on the fuel surface, the maximum flame temperatures and the flame zone length.

Preparation and thermal cross-linking mechanism of co-polyester fiber with flame retardancy and anti-dripping by in situ polymerization

Extensive research has been conducted on polyester flame retardants and anti-droplet modifications in recent years. The conventional methods used to improve the effectiveness of the anti-droplet modifications usually involve improving the melt fluidity and the combustion char formation through reactive cross-linking. However, these methods, while reducing the droplets, may produce more smoke. This study proposes a combustion cross-linking method which avoids the droplet and flame retardancy synergistic modification problem. Based on the flame retardancy of polyester, anti-droplet properties were realized using a collaborative cross – linking structure formed by a phosphorus – containing flame – retardant group and acid silicon solvent to achieve a flame retardant and anti-droplets result. The results show that the phosphorus–silicon copolyester presents an enhancement effect for flame retardancy, confirmed by obvious reductions in the peak value of heat release rate (78.4%) and total heat release (44.2%). Meanwhile, the total smoke release and smoke product rate of phosphorus–silicon copolyester are decreased by 45.1% and 41.5%, respectively. And the phosphorus–silicon copolyester has a high LOI value of 34.8 ± 0.1% and UL-94 is V-0 rating with superior anti-dripping performance. Flame retardancy index (FRI) of the copolyesters containing phosphorus–silica are up to 4.3093 (good flame retardancy). Nonisothermal differential scanning calorimetry (DSC) was performed for qualitative analysis of network formation by the aid of Cure Index (CI) dimensionless criterion. It was observed that the acidic silica led to Excellent cure situation. The TG-DSC, XPS, and FTIR results validate the thermal cross-linking ability of the copolymer due to the synergistic cross-linking effect between the self-cross-linking characteristic of the catalysed acidic silica sol containing the phosphorus flame retardant. The SEM-EDX and Raman results further verify the effectiveness of the condensed-phase flame-retardant mechanism. Phosphorus–silicon copolyester has good spinnability, flame retardancy and anti-droplets properties. Which provides a simple method for preparing polyester by using this combustion synergistic crosslinking effect to achieve flame retardant and anti-dripping modification of copolymers.

Scheme of proposed thermal cross-linking mechanism.

A bio-based phosphaphenanthrene-containing derivative modified epoxy thermosets with good flame retardancy, high mechanical properties and transparency

Phosphorus-containing flame retardants have received huge interest for improving the flame retardant behavior of epoxy resins (EP) over the past few decades. However, a satisfactory flame retardant effect requires high loading of most phosphorus-containing flame retardants, resulting in the deterioration of the thermo-mechanical properties of the flame retardant epoxy materials. To obtain the flame retardant EP with excellent comprehensive properties, a furfurylamine-derived bis-DOPO derivative (FA-bis-DOPO) was synthesized from bio-mass as a co-curing agent for the flame retardant EP. The incorporation of FA-bis-DOPO improved the mechanical strength, the storage modulus and the glass transition temperature of the flame retardant epoxy materials, owing to its stiffness and reactivity with the epoxy matrix to enhance the crosslinking density. The EP material containing 5.0 wt% of FA-bis-DOPO had an LOI of 31.0% and UL-94 V-0 rating, while the pristine EP had an LOI of 23.5% and failed in the UL-94 test, manifesting the high flame retardant efficiency of FA-bis-DOPO. Besides, the cone calorimeter results demonstrated that the PHRR, THR, and TSP values of the EP/FA-bis-DOPO-5.0 were 28.0%, 27.3%, and 9.9% lower than those of the pristine EP, respectively. The flame retardant mechanism of FA-bis-DOPO could be attributed to the combined vapor and condensed phase mechanisms which involved the interruption of the combustion chain reaction by quenching radicals and the inhibition of the transfer of pyrolytic volatile products by catalytic formation of an intact and compact char layer.

Phosphorus-containing flame retardants have received huge interest for improving the flame retardant behavior of epoxy resins (EP) over the past few decades.

Coffee Wastes as Sustainable Flame Retardants for Polymer Materials

Development of green flame retardants has become a core part of the attention of material scientists and technologists in a paradigm shift from general purpose to specific sustainable products. This work is the first report on the use of coffee biowastes as sustainable flame retardants for epoxy, as a typical highly flammable polymer. We used spent coffee grounds (SCG) as well as SCG chemically modified with phosphorus (P-SCG) to develop a sustainable highly efficient flame retardant. A considerable reduction in the peak of heat release rate (pHRR) by 40% was observed in the pyrolysis combustion flow calorimeter analysis (PCFC), which proved the merit of the used coffee biowastes for being used as sustainable flame retardants for polymers. This work would open new opportunities to investigate the impact of other sorts of coffee wastes rather than SCG from different sectors of the coffee industry on polymers of different family.

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.

Flame-Retardant Performance of Epoxy Resin Composites with SiO2 Nanoparticles and Phenethyl-Bridged DOPO Derivative

Flame retardancy of epoxy resin (EP) plays a vital role in its applications. When inorganic nanomaterials form inorganic/organic nanocomposites, they exhibit special flame-retardant effects. In this study, EP nanocomposites were prepared by the incorporation of SiO2 nanoparticles and phenethyl-bridged 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) derivative (DiDOPO), and the synergistic effects of SiO2 nanoparticles and DiDOPO on the flame-retardant performance of EP were discussed. Results indicated that the introduction of only 15 wt % SiO2 and 5 wt % DiDOPO in EP leads to the increase in the limiting oxygen index from 21.8 to 30.2%, and the nanocomposites achieve the UL-94 V-0 rating. Thermogravimetric analysis revealed that char yield increases with the increase in the SiO2 content of the nanocomposites and that an increased amount of thermally stable carbonaceous char is formed. SiO2 nanoparticles can improve the thermal stability and mechanical performance of EP; hence, the nanoparticles can serve as an efficient adjuvant for the DiDOPO/EP flame-retardant system.

The "Materials Chemistry" Section of Molecules: A Multidisciplinary Environment for Materials-Based Researches

The "Materials Chemistry" Section of Molecules is an open access place for the dissemination of theoretical and experimental studies related to the chemical approaches to materials-based problems [...].

Recently Emerging Nanotechnological Advancements in Polymer Nanocomposite Coatings for Anti-corrosion, Anti-fouling and Self-healing

Recent nanotechnological advancements have enabled novel innovations in protective polymer nanocomposites (PNC) coatings for anti-corrosion, anti-fouling and self-healing services on material surfaces. Nanotechnology encompases research, manufacturing, and application of nanoparticulate architectures, tubular structures, sheets or plates exhibiting sizes below 100 nanometers (nm) in at least a single dimension. Inclusions of nanoparticles into organic entities have demonstrated enhanced properties essential for attainiment of aesthetics, anti-corrosion, thermal stability for high-temperature performances, mechanical strength essential for resisting coating deterioration in harsh environments, nano-architectural cross-linking capable of hindering penetration of corrosive, and biofouling entities. Unlike previously published literature, this paper elucidates very recently emerging important advancements in novel techniques utilized in developing PNC coatings for applications in aerospace, packaging, automotive, biomedicine, maritime, and oil and gas industries for attaining superior anti-fouling, anti-corrosion, and self-healing behaviors on critical material surfaces. Emerging market structures and novel applications are also presented.

Effects of Combining Graphene Nanoplatelet and Phosphorous Flame Retardant as Additives on Mechanical Properties and Flame Retardancy of Epoxy Nanocomposite

The effects of combining 0.1–5 wt % graphene nanoplatelet (GNP) and 3–30 wt % phosphorous flame retardant, 9,10- dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) as fillers in epoxy polymer on the mechanical, flame retardancy, and electrical properties of the epoxy nanocomposites was investigated. GNP was homogeneously dispersed into the epoxy matrix using a solvent-free three-roll milling process, while DOPO was incorporated into the epoxy resin by mechanical stirring at elevated temperature. The incorporation of DOPO reduced the crosslinking density of the epoxy resin. When using polyetheramine as a hardener, the structural rigidity effect of DOPO overshadowed the crosslinking effect and governed the flexural moduli of epoxy/DOPO resins. The flexural moduli of the nanocomposites were improved by adding GNP up to 5 wt % and DOPO up to 30 wt %, whereas the flexural strengths deteriorated when the GNP and DOPO loading were higher than 1 wt % and 10 wt %, respectively. Limited by the adverse effects on mechanical property, the loading combinations of GNP and DOPO within the range of 0–1 wt % and 0–10 wt %, respectively, in epoxy resin were further studied. Flame retardancy index (FRI), which depended on three parameters obtained from cone calorimetry, was considered to evaluate the flame retardancy of the epoxy composites. DOPO showed better performance than GNP as the flame retardant additive, while combining DOPO and GNP could further improve FRI to some extent. With the combination of 0.5 wt % GNP and 10 wt % DOPO, improvement in both mechanical properties and flame retardant efficiency of the nanocomposite was observed. Such a combination did not affect the electrical conductivity of the nanocomposites since the percolation threshold was at 1.6 wt % GNP. Our results enhance the understanding of the structure–property relationship of additive-filled epoxy resin composites and serve as a property constraining guidance for the composite manufacturing.

Enhanced Resistance to Fire of the Bark-Based Panels Bonded with Clay

The aim of this study was to investigate the flammability of ecologically friendly, 100% natural larch and poplar bark-based panels bonded with clay. The clay acted as a fire retardant, and it improved the fire resistance of the boards by 12–15% for the surface and 27–39% for the edge of the testing specimens. The thermal conductivity was also analyzed. Although the panels had a density ranging from 600 to 900 kg/m3, thermal conductivity for the panel with a density of 600 kg/m3 was excellent, and it was comparable to lightweight insulation panels with much lower densities. Besides that, the advantage of the bark clay boards, as an insulation material, is mostly in an accumulative capacity similar to wood cement boards, and it can significantly improve the climatic stability of indoor spaces that have low ventilation rates. Bark boards with clay, similar to wood cement composites (wood wool cement composites and wood particle cement composites), have low mechanical properties and elasticity. Therefore, there their use is limited to non-structural paneling applications. These ecologically friendly, 100% natural and recyclable composites can be mostly used with respect to their thermal insulation, acoustics and fire resistance properties.

Flame Retardant Polypropylenes: A Review

Polypropylene (PP) is a commodity plastic known for high rigidity and crystallinity, which is suitable for a wide range of applications. However, high flammability of PP has always been noticed by users as a constraint; therefore, a variety of additives has been examined to make PP flame-retardant. In this work, research papers on the flame retardancy of PP have been comprehensively reviewed, classified in terms of flame retardancy, and evaluated based on the universal dimensionless criterion of Flame Retardancy Index (FRI). The classification of additives of well-known families, i.e., phosphorus-based, nitrogen-based, mineral, carbon-based, bio-based, and hybrid flame retardants composed of two or more additives, was reflected in FRI mirror calculated from cone calorimetry data, whatever heat flux and sample thickness in a given series of samples. PP composites were categorized in terms of flame retardancy performance as Poor, Good, or Excellent cases. It also attempted to correlate other criteria like UL-94 and limiting oxygen index (LOI) with FRI values, giving a broad view of flame retardancy performance of PP composites. The collected data and the conclusions presented in this survey should help researchers working in the field to select the best additives among possibilities for making the PP sufficiently flame-retardant for advanced applications.

Metal-Organic Framework (MOF)/Epoxy Coatings: A Review

Epoxy coatings are developing fast in order to meet the requirements of advanced materials and systems. Progress in nanomaterial science and technology has opened a new era of engineering for tailoring the bulk and surface properties of organic coatings, e.g., adhesion to the substrate, anti-corrosion, mechanical, flame-retardant, and self-healing characteristics. Metal-organic frameworks (MOFs), a subclass of coordinative polymers with porous microstructures, have been widely synthesized in recent years and applied in gas and energy storage, separation, sensing, environmental science and technology, and medicine. Nevertheless, less attention has been paid to their performance in coatings. Well-known as micro- and nanoporous materials, with a tailorable structure consisting of metal ions and organic linkers, MOFs have a huge loading capacity, which is essential for the delivery of corrosion inhibitors. This review paper attempts to highlight the importance of epoxy/MOF composites for coating applications. A particular emphasis was explicitly placed on the anti-corrosion, flame-retardant, mechanical, and dielectric properties of epoxy/MOF coatings.

Recent Developments in the Flame-Retardant System of Epoxy Resin

With the increasing emphasis on environmental protection, the development of flame retardants for epoxy resin (EP) has tended to be non-toxic, efficient, multifunctional and systematic. Currently reported flame retardants have been capable of providing flame retardancy, heat resistance and thermal stability to EP. However, many aspects still need to be further improved. This paper reviews the development of EPs in halogen-free flame retardants, focusing on phosphorus flame retardants, carbon-based materials, silicon flame retardants, inorganic nanofillers, and metal-containing compounds. These flame retardants can be used on their own or in combination to achieve the desired results. The effects of these flame retardants on the thermal stability and flame retardancy of EPs were discussed. Despite the great progress on flame retardants for EP in recent years, further improvement of EP is needed to obtain numerous eco-friendly high-performance materials.

Flame-Retardant Performance of Transparent and Tensile-Strength-Enhanced Epoxy Resins

In this study, a flame-retardant additive with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) groups denoted DSD was successfully synthesized from DOPO, 4,4′-diaminodiphenyl sulfone (DDS), and salicylaldehyde. The chemical structure of DSD was characterized by FTIR–ATR, NMR, and elemental analysis. DSD was used as an amine curing agent, and the transparent, tensile strength-enhanced epoxy resins named EP–DSD were prepared via thermal curing reactions among the diglycidyl ether of bisphenol A (DGEBA), 4,4′-diaminodiphenylmethane (DDM), and DSD. The flame-retardancy of composites was studied by the limiting oxygen index (LOI) and UL-94 test. The LOI values of EP–DSD composites increased from 30.7% for a content of 3 wt % to 35.4% for a content of 9 wt %. When the content of DSD reached 6 wt %, a V-0 rating under the UL-94 vertical test was achieved. SEM photographs of char residues after the UL-94 test indicate that an intumescent and tight char layer with a porous structure inside was formed. The TGA results revealed that EP–DSD thermosets decomposed ahead of time. The graphitization degree of the residual chars was also investigated by laser Raman spectroscopy. The measurement of tensile strength at breaking point shows that the loading of DSD increases the tensile strength of epoxy thermosets. Py-GC/MS analysis shows the presence of phosphorus fragments released during EP–DSD thermal decomposition, which could act as free radical inhibitors in the gas phase. Owing to the promotion of the formation of intumescent and compact char residues in the condensed phase and nonflammable phosphorus fragments formed from the decomposition of DOPO groups, EP–DSD composites displayed obvious flame-retardancy.