On flame retardancy in polycaprolactam composites by aluminium diethylphosphinate and melamine polyphosphate in conjunction with organically modified montmorillonite nanoclay

Phosphorus-Containing Flame-Retardant Benzocyclobutylene Composites with High Thermal Stability and Low CTE

As a component of printed circuit substrate, copper clad laminate (CCL) needs to meet the performance requirements of heat resistance, flame retardancy, and low coefficient of thermal expansion (CTE), which, respectively, affects the stability, safety, and processability of terminal electronic products. In this paper, benzocyclobutylene (BCB)-functionalized phosphorus-oxygen flame retardant composites were prepared through introducing the BCB groups, and the performance was researched by thermogravimetric analysis, microcombustion calorimetry, and thermomechanical analysis. The research results show that these phosphorus oxide compounds containing BCB groups show good thermal stability and low total heat release (THR) after thermal curing, and the more BCB groups on the phosphorus oxide monomers, the better the thermal stability and flame retardancy of cured resins. The T_d5 and THR of the composite (M3) are as high as 443 °C and 23.1 kJ/g, respectively. In addition, the CTE of M3 is as low as 16.71 ppm/°C. Introduction of BCB groups which can be crosslinked through heat to improve the thermal stability, flame retardancy, and reduced CTE of traditional organophosphorus flame retardant materials. These materials are expected to be good candidates for CCL substrates for electronic circuits.

Synthesis of aluminum alkylphosphinates under atmospheric pressure

Alkylphosphinates have received extensive attention in the past few decades because of their very useful mechanical properties, electrical properties, low density, and low toxicity, and have been widely used in flame-retardant materials and other fields. In this work, aluminum diethylphosphinate is successfully synthesized under atmospheric pressure. More importantly, two novel dialkylphosphinates, aluminum dioctylphosphinate and aluminum didecylphosphinate, are first synthesized and characterized. The structures of these aluminum dialkylphosphinates are confirmed by nuclear magnetic resonance, Fourier-transform infrared spectroscopy, and high-resolution mass spectrometry, and the microscopic morphology and thermal stability are analyzed by scanning electron microscopy and thermogravimetric analysis, respectively. Furthermore, conditions for the synthesis of aluminum dioctylphosphinate are optimized. Compared with the traditional method of synthesizing dialkylphosphinates under high pressure, the method reported in this paper has the advantages of high safety, easy operation, and low economic cost, which makes it suitable for industrial production.

Synergistic effect of aluminum diethylphosphinate/sodium stearate modified vermiculite on flame retardant and smoke suppression properties of amino coatings

Various inorganic fillers are proved to be desirable synergists to improve the fire resistance of fire-retardant coatings. Herein, a functional filler (ANE) with flame retardant property was prepared by intercalating aluminum diethylphosphinate into microwave expanded vermiculite and grafting sodium stearate on its surface. The structure of ANE was fully characterized by FTIR, XRD, XPS and SEM analyses. Then ANE was applied to melamine modified urea-formaldehyde resin to produce fire-retardant coatings. The fire resistance test, TGA and cone calorimeter test demonstrate that ANE imparts great heat insulation, thermal stability, and flame retardancy to the coatings. Moreover, the introduction of ANE exhibits an excellent synergistic effect on reducing the heat release and smoke emission of the coatings. Specifically, with the addition of 3 wt% ANE, the heat release rate and smoke density grade of the coatings are decreased by 25.24% and 60.32%, respectively, compared to that without ANE. The excellent flame retardancy and smoke suppression performances of the coatings are mainly attributed to the formation of more cross-linking structures in the carbon layers, resulting in a more stable and compact char structure. In addition, the good hydrophobicity of ANE coatings can ensure the durability of flame retardancy.

Analysis of the Fire Behavior of Polymers (PP, PA 6 and PE-LD) and Their Improvement Using Various Flame Retardants

The fire behavior of polymers is examined primarily with the time-dependent heat release rate (HRR) measured with a cone calorimeter. The HRR is used to examine the fire behavior of materials with and without flame retardants, especially Polypropylene (PP-Copo) and Polyethylene (PE-LD). Polypropylene is stored for up to 99 days under normal conditions and the heat release rate shows especially changes about 100 s after irradiation with cone calorimeter, which may be caused by aging effects. The effect of crosslinking to the burning behavior of PP was examined too. Polyamides (PA 6) are irradiated with a radiation intensity of 25 kW/m² to 95 kW/m² and fire-related principles between radiation intensity and time to ignition can be derived from the measurement results. In order to comprehensively investigate the fire behavior of PP (also with flame retardant additives), the samples were also exposed to a flame, according to UL 94 with small power (50 W) and is inflamed with the power of a few 100 W. The irradiation causes different trigger mechanisms for the flame retardant additives in a plastic than the flame exposure. It is shown that the compound, which is favorable for irradiation, is not necessarily good for flame exposure. It can be seen that expandable graphite alone or with the addition of other additives is a very effective flame retardant for PP.

Fire Properties of Acrylonitrile Butadiene Styrene Enhanced with Organic Montmorillonite and Exolit Fire Retardant

In this paper an experimental investigation on fire retardancy of a new polymer nanocomposite derived from organic montmorillonite and exolit fire retardant in an acrylonitrile- butadiene-styrene copolymer by analyzing the flammability and fire behavior is described. The samples were prepared by melting and mixing nanocomposites and fire retardant in different concentrations in an acrylonitrile-butadiene-styrene base polymer. It was found that using only one component (organic montmorillonite or fire retardant) the burning stops in 10 s on the sample. Confirmation of synergy in flammability by combining both montmorillonite and flame retardants was noticed and is discussed regarding the flame-retardant mechanisms assessed by means of the Limiting oxygen index (LOI), UL 94, and cone-calorimeter methods. The acrylonitrile- butadiene-styrene preparation with 15–20 wt% fire retardant and 1–2 wt% organic montmorillonite reached a UL-94 V-0 classification, contrasting with the pure acrylonitrile- butadiene-styrene and the acrylonitrile-butadiene-styrene with 15 wt% fire retardant and acrylonitrile-butadiene-styrene with 1–2 wt% organic montmorillonite formulations, which completely burned. Finally, the samples showed a very good synergy going to a higher reduction of the peak heat release rate and to a minimum mass reduction, as obtained from cone calorimeter tests.

Thermal Stability, Pyrolysis Behavior, and Fire-Retardant Performance of Melamine Cyanurate@Poly(cyclotriphosphazene-co-4,4'-sulfonyl diphenol) Hybrid Nanosheet-Containing Polyamide 6 Composites

A novel halogen-free highly cross-linked supramolecular poly(cyclotriphosphazene-co-4,4'-sulfonyl diphenol) (PZS)-functionalized melamine cyanurate (MCA) (MCA@PZS) hybrid nanosheet fire-retardant (FR) was synthesized and thoroughly characterized using scanning electron microscopy, Fourier-transform infrared (FTIR), X-ray diffraction, and X-ray photoelectron spectroscopy analyses. The polyamide 6 (PA6) composites comprising MCA, PZS, and the MCA@PZS hybrids were prepared via the melt-blending technique. The thermogravimetric analysis combined with FTIR and mass spectroscopy revealed that during thermal degradation, the PA6/MCA@PZS composites released less toxic gases and small organic volatile compounds than the neat PA6 and composites containing MCA or PZS solely. Moreover, compared to neat PA6, the PA6 composite with a 5 wt % MCA@PZS hybrid exhibited enhanced fire retardation properties, with a 29.4 and 32.1% decrease in the peak heat and total heat release rates, respectively. Besides, the PA6 composites with MCA@PZS-5% content achieved a V-0 rating in the UL-94 test. Finally, based on the obtained results from gaseous and condensed phases, the possible mechanism responsible for improved FR properties of the PA6/MCA@PZS composites was proposed.

Multifunctional Gelcoats for Fiber Reinforced Composites

Achieving special features in polymer composites, such as flame retardancy and thermal and electrical conductivity, often requires the application of different additives, which might negatively affect other properties of the polymer matrix and the composite structure. Furthermore, the application of solid additives in composites produced by liquid transfer moulding can lead to the filtration of the additive by the reinforcement, which causes a non-uniform particle distribution and an uneven performance. An evident solution to address these issues is to apply the additives in a separate layer on the surface of the composite. As in many applications, gelcoats are used to reach appropriate surface quality, a reasonable progression in the composite industry is the development of multifunctional gelcoats. In this article, after a short introduction to gelcoats and their main base materials (unsaturated polyester, epoxy, and others) multifunctional gelcoats are discussed according to their functionality, in particular water resistance, electric conductivity and flame retardancy. Classical and novel gelcoat preparation methods (application by brush and/or roller, spraying, UV-curing, in-mould gelcoating), as well as common defects that occur during gelcoating are discussed. Finally, the testing methods of multifunctional gelcoats are outlined.

Flame Retardant Polyamide Fibres: The Challenge of Minimising Flame Retardant Additive Contents with Added Nanoclays

This work shows that halogen-free, flame retarded polyamide 6 (PA6), fabrics may be produced in which component fibres still have acceptable tensile properties and low levels (preferably ≤10 wt %) of additives by incorporating a nanoclay along with two types of flame retardant formulations. The latter include (i) aluminium diethyl phosphinate (AlPi) at 10 wt %, known to work principally in the vapour phase and (ii) ammonium sulphamate (AS)/dipentaerythritol (DP) system present at 2.5 and 1 wt % respectively, believed to be condense phase active. The nanoclay chosen is an organically modified montmorillonite clay, Cloisite 25A. The effect of each additive system is analysed in terms of its ability to maximise both filament tensile properties relative to 100% PA6 and flame retardant behaviour of knitted fabrics in a vertical orientation. None of the AlPi-containing formulations achieved self-extinguishability, although the presence of nanoclay promoted lower burning and melt dripping rates. The AS/DP-containing formulations with total flame retardant levels of 5.5 wt % or less showed far superior properties and with nanoclay, showed fabric extinction times ≤ 39 s and reduced melt dripping. The tensile and flammability results, supported by thermogravimetric analysis, have been interpreted in terms of the mechanism of action of each flame retardant/nanoclay type.

Synergistic effects of nano-silica on aluminum diethylphosphinate/polyamide 66 system for fire retardancy

Nano-silica had been used as a synergistic agent for the preparation of aluminum diethylphosphinate (AlPi) flame retardant polyamide 66 (PA66/AlPi) and PA66/AlPi/nano-silica composites through twin-screw extrusion. The limiting oxygen index (LOI), used to characterize the minimum amount of oxygen needed to sustain a candle-like flame, revealed that the PA66/10%AlPi/1%nano-silica composites exhibited an excellent flame retardant efficiency with a high LOI value of 32.3%. The vertical flame test (UL-94) revealed that the PA66/10%AlPi/1%nano-silica composites passed the V-0 rating without drop melting. Cone calorimeter test revealed that the heat release rate and total heat rate for the PA66/10%AlPi/1%nano-silica composites were significantly decreased by 51.1 and 16.8%, respectively, compared with those of pure PA66. The thermogravimetric analysis showed that the PA66/10%AlPi/1%nano-silica composites had vast chars of 8.1% even at 800°C, indicating that nano-silica could promote the char formation of the PA66 composites. Scanning electron microscopy indicated a solid and tough residue of the burned PA66/10%AlPi/1%nano-silica composites as compared with the very loose and brickle residue of the burned pure PA66, indicating that a suitable amount of nano-silica played a synergistic effect in the flame retardancy.