Pyrolysis of epoxy resins and fire behavior of epoxy resin composites flame-retarded with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide additives

Thermal degradation behavior and flame retardant properties of PET/DiDOPO conjugated flame retardant composites*

PET/DIDOPO conjugated flame retardant composites were prepared by melt blending of styrene bridged DOPO (DIDOPO) into polyethylene terephthalate (PET). The flame retardancy, rheological behavior, and thermal degradation behavior of the composite were characterized by vertical combustion test (UL-94), limit oxygen index test (LOI), rotational rheometer, and thermogravimetry (TG). The results showed that the flame retardant composite with V-0 grade was obtained when the amount of DIDOPO is 12.5wt%, and the corresponding LOI value was 56.87% higher than that of PET. The thermogravimetry-fourier infrared spectroscopy (TG-FTIR) test results showed that DIDOPO could promote the degradation of PET/DIDOPO materials, and release phosphorus-containing free radicals to quench the flame, therefore slowing down the combustion process, and mainly playing the key flame retardant role in gas-phase.

A Phosphorous-Based Bi-Functional Flame Retardant Based on Phosphaphenanthrene and Aluminum Hypophosphite for an Epoxy Thermoset

A phosphorous-based bi-functional compound HPDAl was used as a reactive-type flame retardant (FR) in an epoxy thermoset (EP) aiming to improve the flame retardant efficiency of phosphorus-based compounds. HPDAl, consisting of two different P-groups of aluminum phosphinate (AHP) and phosphophenanthrene (DOPO) with different phosphorous chemical environments and thus exerting different FR actions, exhibited an intramolecular P-P groups synergy and possessed superior flame-retardant efficiency compared with DOPO or AHP alone or the physical combination of DOPO/AHP in EP. Adding 2 wt.% HPDAl made EP composites acquire a LOI value of 32.3%, pass a UL94 V-0 rating with a blowing-out effect, and exhibit a decrease in the heat/smoke release. The flame retardant modes of action of HPDAl were confirmed by the experiments of the scanning electron microscope (SEM), X-ray photoelectron spectroscopy (XPS), and thermogravimetry–Fourier transform infrared spectroscopy–gas chromatograph/mass spectrometer (TG-FTIR-GC/MS). The results indicate that the phosphorous-based FRs show different influences on the flame retardancy of composites, mainly depending on their chemical structures. HPDAl had a flame inhibition effect in the gas phase and a charring effect in the condensed phase, with a well-balanced distribution of P content in the gas/condensed phase. Furthermore, the addition of HPDAl hardly impaired the mechanical properties of the matrix due to the link by chemical bonds between them.

Mode of Action of Zn-DOPOx and Melamine Polyphosphate as Flame Retardants in Glass Fiber-Reinforced Polyamide 66

In this study, the flame retardant effect of the Zn salt of 10-hydroxy-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (Zn-DOPOx), melamine polyphosphate (MPP) and their mixture was investigated towards the mode of action in glass fiber-reinforced polyamide 66 (PA 66 GF). The flammability was evaluated using UL 94 V and cone calorimetry. Influence on char formation was analyzed by SEM. Thermal decomposition of Zn-DOPOx and MPP was studied by TGA and ATR-FTIR. The release of gaseous PA 66 decomposition products was investigated using TGA-DTA-FTIR. Combining Zn-DOPOx and MPP leads to an improvement in flame retardancy, most pronounced for equal parts of weight. Mode of action changes significantly for Zn-DOPOx:MPP (1:1) compared to the sole components and a strong interaction between Zn-DOPOx and MPP is revealed, resulting in a more open char structure. Fuel dilution as well as less exothermic decomposition are essential for the mode of action of the combination. Through low HRR values and high CO/CO₂ ratio during cone calorimetry measurements, a significant increase in gas phase activity was proven. Therefore, it is concluded that Zn-DOPOx:MPP (1:1) leads to a significant increase in flame retardancy through a combination of mode of actions in the gas and condensed phase resulting from the change in thermal stability.

The Influence of Flame Retardants on Combustion of Glass Fiber-Reinforced Epoxy Resin

For the first time, next to the flammability tests (LOI, UL-94 HB, VBB, TGA), experimental tests and computer simulation have been conducted on the flame spread and combustion of glass fiber-reinforced epoxy resins (GFRER) with 6% graphene and 6% DDM-DOPO flame-retardant additives. The downward rates of flame spread (ROS) in opposed flow with oxidizer and the upward ROS along GFRER composites have been first measured as well as the distribution of temperature over the combustion surface of the composites with flame-retardant additives and without them. The LOI and UL-94 HB tests showed a reduction in the flammability of GFRER when flame retardants were added and predicted a higher effectiveness of DDM-DOPO compared to graphene. Adding DDM-DOPO resulted in increasing the rate of formation of the volatile pyrolysis products and their yield, indicating, together with the other data obtained, the gas phase mechanism of the flame retardant’s action. Adding graphene resulted in an increase in the soot release on the burning surface and an increase in the amount of non-volatile pyrolysis products on the burning surface, reducing the amount of fuel that participated in the oxidation reactions in the gas phase. The developed numerical combustion model for GFRER with a DDM-DOPO additive, based on the action of DDM-DOPO as a flame retardant acting in the gas phase, satisfactorily predicts the effect of this flame retardant on the reduction in downward ROS over GFRER for 45–50% oxygen concentrations. The developed model for GFRER with graphene additive, based on a reduction in the amount of fuel and increase in the amount of incombustible volatile pyrolysis products when graphene is added, predicts with good accuracy downward ROS over GFRER depending on oxygen concentration.

Thermal treatment of carbon-fibre-reinforced polymers (Part 2: Energy recovery and feedstock recycling)

The use of carbon fibre (CF)-reinforced plastics has grown significantly in recent years, and new areas of application have been and are being developed. As a result, the amount of non-recyclable waste containing CF is also rising. There are currently no treatment methods for this type of waste. Within this project different approaches for the treatment of waste containing CF were investigated. Main subject of the research project were large-scale investigations on treatment possibilities and limits of waste containing CF in high temperature processes, with focus on the investigation of process-specific residues and possible fibre emission. The results showed that the two conventional thermal waste treatment concepts with grate and rotary kiln firing systems are not suitable for a complete oxidation of CFs due to the insufficient process conditions (temperature and dwell time). The CFs were mainly discharged via the bottom ash/slag. Due to the partial decomposition during thermal treatment, World Health Organization (WHO) fibres occurred in low concentrations. The tests run in the cement kiln plant have shown the necessity of comminution for waste containing CF. With respect to the short testing times and moderate quantities of inserted CF, a final evaluation of the suitability of this disposal path was not possible. The use of specially processed waste containing CF (carbon-fibre-reinforced plastic (CFRP) pellets) as a carbon substitute in calcium carbide production led to high carbon conversion rates. In the unburned furnace dust, which is marketed as a by-product of the process, CFs in relevant quantities could be detected.

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.

Transparent low-flammability epoxy resins using a benzoguanamine-based DOPO derivative

We successfully prepared a highly effective flame-retardant additive called hsalbenzoguanamine phosphaphenanthrene (HDPD) through salicylaldehyde and nitrogen-rich benzoguanamine. The introduction of HDPD into epoxy resin (EP) sharply enhanced the flame retardancy of EP/HDPD thermosets. The introduction of 6 wt% HDPD into EP succeeded in reaching the V-0 rating. Limited oxygen index results revealed the high flame-retarding performance of HDPD. Cone calorimeter test data revealed that heat and smoke released from EP/6 wt% HDPD thermoset were significantly restrained. In addition, EP/6 wt% HDPD thermoset demonstrated excellent transmittance and mechanical strength. The transmittance of EP/6 wt% HDPD was assessed from 520 to 800 nm. The results showed that transmittance of EP/6 wt% HDPD were nearly 90% of the control group.

Nanostructured Surface Finishing and Coatings: Functional Properties and Applications

This review presents current literature on different nanocomposite coatings and surface finishing for textiles, and in particular this study has focused on smart materials, drug-delivery systems, industrial, antifouling and nano/ultrafiltration membrane coatings. Each of these nanostructured coatings shows interesting properties for different fields of application. In this review, particular attention is paid to the synthesis and the consequent physico-chemical characteristics of each coating and, therefore, to the different parameters that influence the substrate deposition process. Several techniques used in the characterization of these surface finishing coatings were also described. In this review the sol-gel method for preparing stimuli-responsive coatings as smart sensor materials is described; polymers and nanoparticles sensitive to pH, temperature, phase, light and biomolecules are also treated; nanomaterials based on phosphorus, borates, hydroxy carbonates and silicones are used and described as flame-retardant coatings; organic/inorganic hybrid sol-gel coatings for industrial applications are illustrated; carbon nanotubes, metallic oxides and polymers are employed for nano/ultrafiltration membranes and antifouling coatings. Research institutes and industries have collaborated in the advancement of nanotechnology by optimizing conversion processes of conventional materials into coatings with new functionalities for intelligent applications.

Intrinsically flame-retardant polyamide 66 with high flame retardancy and mechanical properties

The key factor in the synthesis of intrinsic flame retardant polymers is the thermal stability and reactivity of phosphorus-based flame retardants. However, it is difficult to realize both thermal stability and high reactivity by using one phosphorus-based flame retardant. Herein, we proposed a strategy to improve the thermal stability of highly reactive flame-retardant, 4-(2-(((2-carboxyethyl)(phenyl)phosphoryl)oxy)ethoxy)-4-oxohexanoic acid (CPPOA), by reacting it with 1,6-diaminohexane to obtain CPPOA salt, which then was copolymerized with PA66 salt to obtain intrinsic flame-retardant polyamide 66 (FRPA66). The thermal stability of CPPOA was significantly improved. The LOI and vertical combustion grade of FRPA66 with 6 wt% CPPOA reached 27.2% and V-0 rating, respectively. Furthermore, the tensile strength and impact strength of the FRPA66 reached 70 MPa and 5.6 kJ m-2, respectively. Our work presents an efficient approach to synthesize polymers having high flame retardancy and good mechanical properties, showing high potential for real applications.

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.

Synthesis of chitosan-based flame retardant and its fire resistance in epoxy resin

A novel flame retardant CCD was synthesized by the condensation between cinnamalde and chitosan, followed by the addition reaction with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide(DOPO), and CCD was named from the initials of the three raw materials. The intermediate product CC and the target product CCD was then characterized by infrared spectrometry and elemental analysis. The flame retardancy of EP thermosets modified by CCD was dramatically improved. Epoxy resin (EP) with 10wt% CCD passed vertical burning (UL-94) V-0 rating and possessed limited oxygen index (LOI) value of 31.6 %. Cone calorimeter test exhibited the introduction of 3.5g CCD into 35g EP decreased the total heat release by 38.8 % and decreased the total smoke product by 72.0 %. XPS, FTIR, SEM and Raman tests were proceeded to determine the char residue for EP/10 % CCD thermoset, and the results showed that char residue for EP/10 % CCD thermoset possessed dense and compact structure which played a positive effect in blocking the exchange of heat and gas.

Flame Retardant Submicron Particles via Surfactant-Free RAFT Emulsion Polymerization of Styrene Derivatives Containing Phosphorous

The reversible addition–fragmentation chain transfer (RAFT) emulsion polymerization of diethyl-(4-vinylbenzyl) phosphate (DEVBP) was performed using PEG-TTC as a macro RAFT agent. PEG-TTC (M_W 2000, 4000) was synthesized by the esterification of poly (ethylene glycol) methyl ether with a carboxylic-terminated RAFT agent, composed a hydrophilic poly (ethylene glycol) (PEG) block and a hydrophobic dodecyl chain. The RAFT emulsion polymerization of DEVBP was well–controlled with a narrow molecular size distribution. Dynamic light scattering and confocal laser scanning microscopy were used to examine the PEG-b-PDVBP submicron particles, and the length of the PEG chain (hydrophilic block) was found to affect the particle size distribution and molecular weight distribution. The submicron particle size increased with increasing degree of polymerization (35, 65, and 130), and precipitation was observed at a high degree of polymerization (DP) using low molecular weight PEG-TTC (DP 130, A3). The flame retardant properties of the PEG-b-PDVBP were evaluated by thermogravimetric analysis (TGA) and micro cone calorimeter (MCC). In the combustion process, the residue of PEG-b-PDEVBP were above 500 °C was observed (A1 ~ B3, 27 ~ 38%), and flame retardant effect of PEG-b-PDEVBP submicron particles/PVA composite were confirmed by increasing range of temperature and decreasing total heat release with increasing contents of PEG-b-PDEVBP. The PEG-b-PDEVBP submicron particles can provide flame retardant properties to aqueous, dispersion and emulsion formed organic/polymer products.

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.

Phosphorus-Containing Flame Retardants from Biobased Chemicals and Their Application in Polyesters and Epoxy Resins

Phosphorus-containing flame retardants synthesized from renewable resources have had a lot of impact in recent years. This article outlines the synthesis, characterization and evaluation of these compounds in polyesters and epoxy resins. The different approaches used in producing biobased flame retardant polyesters and epoxy resins are reported. While for the polyesters biomass derived compounds usually are phosphorylated and melt blended with the polymer, biobased flame retardants for epoxy resins are directly incorporated into the polymer structure by a using a phosphorylated biobased monomer or curing agent. Evaluating the efficiency of the flame retardant composites is done by discussing results obtained from UL94 vertical burning, limiting oxygen index (LOI) and cone calorimetry tests. The review ends with an outlook on future development trends of biobased flame retardant systems for polyesters and epoxy resins.