Fire-Safe Polymer Composites: Flame-Retardant Effect of Nanofillers

Enhancing the Fire Resistance of Ablative Materials: Role of the Polymeric Matrix and Silicon Carbide Reinforcement

The primary characteristic of ablative materials is their fire resistance. This study explored the development of cost-effective ablative materials formed into application-specific shapes by using a polymer matrix reinforced with ceramic powder. A thermoplastic (polypropylene; PP) and a thermoset (polyester; UPE) matrix were used to manufacture ablative materials with 50 wt% silicon carbide (SiC) particles. The reference composites (50 wt% SiC) were compared to those with 1 and 3 wt% short glass fibers (0.5 mm length) and to composites using a 1 and 3 wt% glass fiber mesh. Fire resistance was tested using a butane flame (900 °C) and by measuring the transmitted heat with a thermocouple. Results showed that the type of polymer matrix (PP or UPE) did not influence fire resistance. Composites with short glass fibers had a fire-resistance time of 100 s, while those with glass fiber mesh tripled this resistance time. The novelty of this work lies in the exploration of a specific type of material with unique percentages of SiC not previously studied. The aim is to develop a low-cost coating for industrial warehouses that has improved fire-protective properties, maintains lower temperatures, and enhances the wear and impact resistance.

Facile and Bioinspired Approach from Gallic Acid for the Synthesis of Biobased Flame Retardant Coatings of Basalt Fibers

A sustainable, bioinspired approach to functionalize basalt fibers with an innovative gallic acid (GA)-iron phenyl phosphonate complex (BF-GA-FeP), for the purpose of improving the flame retardancy in composite materials, is developed. BFs were at first pretreated with O3, obtaining surface free hydroxyl groups that allowed the subsequent covalent immobilization of biosourced GA units on the fiber through ester linkages. Phenolic -OH groups of the GA units were then exploited for the complexation of iron phenyl phosphonate, resulting in the target-complex-coated BF fiber (BF-GA-FeP). Microwave plasma atomic emission spectroscopy and scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy analyses of BF-GA-FeP highlighted an increase in iron content, modification of fiber morphology, and occurrence of phosphorus, respectively. BFs, modified with a low amount of the developed complex, were used to reinforce a poly(lactic acid) (PLA) matrix in the production of a biocomposite (PLA/BF-FeP). PLA/BF-FeP showed a higher thermal stability than neat PLA and PLA reinforced with untreated BFs (PLA/BF), as confirmed by thermogravimetric analysis. The cone calorimeter test highlighted several advantages for PLA/BF-FeP, including a prolonged time to ignition, a reduced time to flame out, an 8% decrease in the peak heat release rate, and a 15% reduced fire propagating index compared to PLA/BF.

Clay-reinforced PVC composites and nanocomposites

Clay-reinforced polyvinyl chloride (PVC) composites and nanocomposites are one of the newest and most important compounds studied and used in various applications, including the biomedical, automotive industry, water treatment, packaging, fire retarding, and construction. The most important clays used in the synthesis of these composites are Bentonite, Montmorillonite, Kaolinite, and Illite. The addition of these nanoclays to the PVC matrix improves mechanical properties, thermal stability, and yellowness index properties. In this chapter, a detailed study of PVC and its properties, types of nanoclays and their properties, modification of nanoclays, production methods of composites, and nanocomposites of PVC/clay, their characterization, and applications have been performed. Herein, the types, properties, and applications of PVC/clay nanocomposites, as well as their challenges and future remarks, are reviewed.

Synergistic interaction between scrap tyre and plastics for the production of sulphur-free, light oil from fast co-pyrolysis

Fast co-pyrolysis offers a sustainable solution for upcycling polymer waste, including scrap tyre and plastics. Previous studies primarily focused on slow heating rates, neglecting synergistic mechanisms and sulphur transformation in co-pyrolysis with tyre. This research explored fast co-pyrolysis of scrap tyre with polypropylene (PP), low-density polyethylene (LDPE), and polystyrene (PS) to understand synergistic effects and sulphur transformation mechanisms. A pronounced synergy was observed between scrap tyre and plastics, with the nature of the synergy being plastic-type dependent. Remarkably, blending 75 wt% PS or LDPE with tyre effectively eliminated sulphur-bearing compounds in the liquid product. This reduction in sulphur content can substantially mitigate the release of hazardous materials into the environment, emphasizing the environmental significance of co-pyrolysis. The synergy between PP or LDPE and tyre amplified the production of lighter hydrocarbons, while PS's interaction led to the creation of monocyclic aromatics. These findings offer insights into the intricate chemistry of scrap tyre and plastic interactions and highlight the potential of co-pyrolysis in waste management. By converting potential pollutants into valuable products, this method can significantly reduce the release of hazardous materials into the environment.

Plastic waste as pyrolysis feedstock for plastic oil production: A review

Turning plastic waste into plastic oil by pyrolysis is one of the promising techniques to eradicate plastic waste pollution and accelerate the circular economy of plastic materials. Plastic waste is an attractive pyrolysis feedstock for plastic oil production owing to its favorable chemical properties of proximate analysis, ultimate analysis, and heating value other than its abundant availability. Despite the exponential growth of scientific output from 2015 to 2022, a vast majority of the current review articles cover the pyrolysis of plastic waste into a series of fuels and value-added products, and up-to-date reviews exclusively on plastic oil production from pyrolysis are relatively scarce. In light of this void in the current review articles, this review attempts to provide an up-to-date overview of plastic waste as pyrolysis feedstock for plastic oil production. A particular emphasis is placed on the common types of plastic as primary sources of plastic pollution, the characteristics (proximate analysis, ultimate analysis, hydrogen/carbon ratio, heating value, and degradation temperature) of various plastic wastes and their potential as pyrolysis feedstock, and the pyrolysis systems (reactor type and heating method) and conditions (temperature, heating rate, residence time, pressure, particle size, reaction atmosphere, catalyst and its operation modes, and single and mixed plastic wastes) used in plastic waste pyrolysis for plastic oil production. The characteristics of plastic oil from pyrolysis in terms of physical properties and chemical composition are also outlined and discussed. The major challenges and future prospects for the large-scale production of plastic oil from pyrolysis are also addressed.

Dual char-forming strategy driven MXene-based fire-proofing epoxy resin coupled with good toughness

It is challenging that the functionalized MXene-based nanofillers are designed to modify the inherent flammability and poor toughness of epoxy polymeric materials and further to facilitate the application of EP composites. Herein, silicon-reinforced Ti₃C₂T_x MXene-based nanoarchitectures (MXene@SiO₂) are synthesized by simple self-growth method, and its enhancement effects on epoxy resin (EP) are investigated. The as-prepared nanoarchitectures realize homogeneous dispersion in EP matrix, indicating well performance-enhancing potential. The incorporation of MXene@SiO₂ achieves improved thermal stability for EP composites with higher T_-5% and lower R_max values. Moreover, EP/2 wt% MXene@SiO₂ composites obtain a 30.2% and 34.0% reduction in peak heat release rate (PHRR) and peak smoke production rate (PSPR) compared to those of pure EP, respectively, also achieving a 52.5% fall in smoke factor (SF) values and increased yield and stability of chars. The dual char-forming effects of MXene@SiO₂ nanoarchitectures, including the catalytic charring of MXene and the migration of SiO₂ to induce charring, are accounted for the results, as well as lamellar barrier effects. Additionally, EP/MXene@SiO₂ composites achieve an enhanced storage modulus of 51.5%, along with improved tensile strength and elongation at break, compared to those of pure EP.

Fly Ash-Incorporated Polystyrene Nanofiber Membrane as a Fire-Retardant Material: Valorization of Discarded Materials

Reusing or recycling waste into new useful materials is essential for environmental protection. Herein, we used discarded polystyrene (PS) and fly-ash (FA) particles and a fabricated fly-ash incorporated polystyrene fiber (FA/PS fiber) composite. The electrospinning process produced continuous PS fibers with a good distribution of FA particles. The prepared nanofibers were characterized by state-of-the-art techniques. The performances of the composite nanofibers were tested for fire-retardant applications. We observed that the incorporation of FA particles into the PS fibers led to an improvement in the performance of the composite as compared to the pristine PS fibers. This study showed an important strategy in using waste materials to produce functional nanofibers through an economical procedure. We believe that the strategy presented in this paper can be extended to other waste materials for obtaining nanofiber membranes for various environmental applications.

Flame Retardant Coatings: Additives, Binders, and Fillers

This review provides an intensive overview of flame retardant coating systems. The occurrence of flame due to thermal degradation of the polymer substrate as a result of overheating is one of the major concerns. Hence, coating is the best solution to this problem as it prevents the substrate from igniting the flame. In this review, the descriptions of several classifications of coating and their relation to thermal degradation and flammability were discussed. The details of flame retardants and flame retardant coatings in terms of principles, types, mechanisms, and properties were explained as well. This overview imparted the importance of intumescent flame retardant coatings in preventing the spread of flame via the formation of a multicellular charred layer. Thus, the intended intumescence can reduce the risk of flame from inherently flammable materials used to maintain a high standard of living.

Toward a New Generation of Fire-Safe Energy Storage Devices: Recent Progress on Fire-Retardant Materials and Strategies for Energy Storage Devices

Over the last few decades, tremendous progress has been achieved in the development of advanced materials for energy storage devices. These achievements have largely enabled the adoption and transition to key technologies such as mobile phones, electric vehicles, and internet of things. However, the recent surge in fire accidents and explosions emanating from energy storage devices have been closely associated with the highly flammable components that make up these devices which have often led to the loss of life and property. Therefore, replacing flammable materials with fire retardant materials has been recognized as the critical solution to the ever-growing fire problem in these devices. This review summarizes the progress achieved so far in the field of fire retardant materials for energy storage devices. Finally, a perspective on the current state of the art is provided, and a future outlook for these fire-retardant materials, strategies, and new characterization methods is discussed.

Recent Advances in the Development of Fire-Resistant Biocomposites—A Review

Biocomposites reinforced with natural fibers represent an eco-friendly and inexpensive alternative to conventional petroleum-based materials and have been increasingly utilized in a wide variety of industrial applications due to their numerous advantages, such as their good mechanical properties, low production costs, renewability, and biodegradability. However, these engineered composite materials have inherent downsides, such as their increased flammability when subjected to heat flux or flame initiators, which can limit their range of applications. As a result, certain attempts are still being made to reduce the flammability of biocomposites. The combustion of biobased composites can potentially create life-threatening conditions in buildings, resulting in substantial human and material losses. Additives known as flame-retardants (FRs) have been commonly used to improve the fire protection of wood and biocomposite materials, textiles, and other fields for the purpose of widening their application areas. At present, this practice is very common in the construction sector due to stringent fire safety regulations on residential and public buildings. The aim of this study was to present and discuss recent advances in the development of fire-resistant biocomposites. The flammability of wood and natural fibers as material resources to produce biocomposites was researched to build a holistic picture. Furthermore, the potential of lignin as an eco-friendly and low-cost FR additive to produce high-performance biocomposites with improved technological and fire properties was also discussed in detail. The development of sustainable FR systems, based on renewable raw materials, represents a viable and promising approach to manufacturing biocomposites with improved fire resistance, lower environmental footprint, and enhanced health and safety performance.

Study on the Flame Retardancy and Hazard Evaluation of Poly(acrylonitrile-co-vinylidene chloride) Fibers by the Addition of Antimony-Based Flame Retardants

Antimony oxide (ATO) is used mainly as a flame retardant, but it is classified as a hazardous substance. Therefore, regulations on the use of antimony trioxide (ATO(3)) and antimony pentoxide (ATO(5)) in textile products are being developed. Accordingly, there is a need for alternative flame retardants. In this study, antimony tetroxide (ATO(4)), which has higher thermal stability and resistance to acids and alkalis than ATO(3) or ATO(5), was selected to assess its use as an alternative flame retardant. First, ATO(3) or ATO(4) were added to poly(acrylonitrile-co-vinylidene chloride) (PANVDC), and the film and wet-spun fiber were prepared. The PANVDC film with flame retardants was prepared to evaluate the flame retardancy and the mechanism of action of the flame retardants. Flame retardancy analysis showed that a limiting oxygen index of 31.2% was obtained when ATO(4) was added, which was higher than when ATO(3) was used. Subsequently, PANVDC fibers with antimony oxide were manufactured and showed improved mechanical and thermal properties when ATO(4) was used, compared to when ATO(3) was tested. In addition, migration analysis due to antimony in the fiber confirmed that the elution amount was below the acceptable standard when PANVDC fibers with ATO(4) were added. Therefore, based on these results, the flame-retardant and thermal properties of antimony tetroxide were superior to antimony trioxide, and it was confirmed that ATO(4) could be used as an alternative flame retardant to ATO(3).

Nanotechnology in Fire Protection-Application and Requirements

Nanotechnology is used, to an increasing extent, in practically every aspect of the economy and society. One area where nanotechnology is constantly advancing is fire protection. Nanostructures are found in elements used in direct protection, such as in protective clothing, filters, and helmets. Solutions in the field of nanotechnology are also used in elements reducing the fire risk and increasing the fire safety, such as building materials and structures, paints, coatings, or fire safety equipment (e.g., fire detectors). However, new solutions may also pose a threat to the safety of people and the environment. As a result of operation or combustion and degradation processes, the emission of nano-substances with toxic properties may occur. Therefore, knowledge in this field is necessary, as it allows for the appropriate targeting and use of nanotechnology.

Fire Behavior of Wood-Based Composite Materials

Wood-based composites such as wood plastic composites (WPC) are emerging as a sustainable and excellent performance materials consisting of wood reinforced with polymer matrix with a variety of applications in construction industries. In this context, wood-based composite materials used in construction industries have witnessed a vigorous growth, leading to a great production activity. However, the main setbacks are their high flammability during fires. To address this issue, flame retardants are utilized to improve the performance of fire properties as well as the flame retardancy of WPC material. In this review, flame retardants employed during manufacturing process with their mechanical properties designed to achieve an enhanced flame retardancy were examined. The addition of flame retardants and manufacturing techniques applied were found to be an optimum condition to improve fire resistance and mechanical properties. The review focuses on the manufacturing techniques, applications, mechanical properties and flammability studies of wood fiber/flour polymer/plastics composites materials. Various flame retardant of WPCs and summary of future prospects were also highlighted.