Novel Core-Shell Hybrid Nanosphere towards the Mechanical Enhancement and Fire Retardance of Polycarbonate

Advanced Flame-Retardant Methods for Polymeric Materials

Most organic polymeric materials have high flammability, for which the large amounts of smoke, toxic gases, heat, and melt drips produced during their burning cause immeasurable damages to human life and property every year. Despite some desirable results having been achieved by conventional flame-retardant methods, their application is encountering more and more difficulties with the ever-increasing high flame-retardant requirements such as high flame-retardant efficiency, great persistence, low release of heat, smoke, and toxic gases, and more importantly not deteriorating or even enhancing the overall properties of polymers. Under such condition, some advanced flame-retardant methods have been developed in the past years based on "all-in-one" intumescence, nanotechnology, in situ reinforcement, intrinsic char formation, plasma treatment, biomimetic coatings, etc., which have provided potential solutions to the dilemma of conventional flame-retardant methods. This review briefly outlines the development, application, and problems of conventional flame-retardant methods, including bulk-additive, bulk-copolymerization, and surface treatment, and focuses on the raise, development, and potential application of advanced flame-retardant methods. The future development of flame-retardant methods is further discussed.

Epoxy/melamine polyphosphate modified silicon carbide composites: Thermal conductivity and flame retardancy analyses

Silicon carbide (SiC) was modified by melamine polyphosphate (MPP)-modified silicone to form SiC-MPP, then incorporated into epoxy resin (EP) for developing thermally resistant composites, which showed thermal conductivity and flame retardancy performance. The EP/SiC-MPP composites were prepared by blending and cured under 60°C for 2 h and 150°C for 8 h. The grafting degree of SiC-MPP was analyzed using Fourier transform Infrared, scanning electron microscope, and thermogravimetric measurements. The flame retardancy of the EP/SiC-MPP composites was studied by UL-94 vertical combustion and cone calorimetry test. The results showed that for EP/SiC-MPP containing 20 wt%, the UL-94 was case V1. Also compared to pure epoxy, the peak heat release rate (PHRR) of composites was reduced from 800 to 304 kW·m−2. The thermal conductivity of EP/SiC-M20 composites was 0.53 W·m−1·K−1, almost 2.5-fold higher than pure epoxy (0.21 W·m−1·K−1). The as-prepared EP/SiC-MPP composites exhibited enhanced flame retardancy and thermal conductivity. Based on analyses performed, these composites took credit-related applications.

A Phosphorous-Containing Bio-Based Furfurylamine Type Benzoxazine and Its Application in Bisphenol-A Type Benzoxazine Resins: Preparation, Thermal Properties and Flammability

Polybenzoxazine (PBa) composites based on phosphorous-containing bio-based furfurylamine type benzoxazines (D-fu) and bisphenol-A type benzoxazines (Ba) were developed for flame retardation. The structure of D-fu was analyzed by Fourier transform infrared (FTIR) spectroscopy and ¹H-NMR spectroscopy. The curing temperature of Ba/D-fu mixtures was systematically studied by differential scanning calorimetry (DSC). Thermogravimetric analysis (TGA) demonstrated the excellent char formation ability of the PBa composites with the addition of phosphorous-containing D-fu. The flame retardancy of the PBa composite materials was tested by the limited oxygen index (LOI), vertical burning test (UL-94) and cone calorimeter (CONE). The LOI and UL-94 level of PBa/PD-fu-5% reached 34 and V0 rate, respectively. Notably, the incorporation of 5% D-fu into PBa led to a decrease of 21.9% at the peak of the heat-release rate and a mass-loss reduction of 8.0%. Moreover, the fire performance index increased, which demonstrated that the introduction of D-fu can diminish fire occurrence. The role of D-fu in the condensed and gas phases for the fire-resistant mechanism of the PBa matrix was supported by SEM-EDS and TGA/infrared spectrometry (TG-FTIR), respectively. Dynamic mechanical analysis (DMA) revealed that the Tg of PBa flame-retardant composites was around 230 °C. Therefore, PBa composites are promising fire-retardant polymers that can be applied as high-performance functional materials.

Fabrication and Mechanism Study of Cerium-Based P, N-Containing Complexes for Reducing Fire Hazards of Polycarbonate with Superior Thermostability and Toughness

A superior comprehensive performance is essential for the extensive utilization of polymers. Current flame-retardant strategies for polycarbonates (PCs) usually realize satisfied fire resistance at the cost of thermostability, toughness, and/or mechanical robustness. Thus, we report a rare-earth-based P, N-containing complex with a lamellar aggregated structure [Ce(DPA)3] by a coordination reaction between a tailored ligand and cerium(III) nitrate. The results indicate that incorporating 3 wt % Ce(DPA)3 enables the resultant PC composite to achieve UL-94 V-0 rating, with a 55% reduction in the peak heat release rate. Besides, the initial (T5) and maximum (Tmax1 and Tmax2) decomposition temperatures are significantly increased by 21, 19, and 27 °C, respectively, in an air atmosphere. Moreover, the impact strength and elongation at break of the PC composite containing 3 wt % Ce(DPA)3 are greatly increased by 20 and 59%, respectively, relative to pristine PC, while its tensile strength (57 MPa) is still close to that of bulk PC (60 MPa). Notably, this work provides a novel methodology for revealing the evolution mechanisms of chemical structures of vapor and residual products during thermal decomposition, which is conducive to guiding fire and heat resistance modification of PC in the future.

Epoxidized Block and Statistical Copolymers Reinforced by Organophosphorus-Titanium-Silicon Hybrid Nanoparticles: Morphology and Thermal and Mechanical Properties

Glycidyl methacrylate (GMA) and a mixture of alkyl methacrylates (average chain length of 13 carbons; termed C13MA; derived from vegetable oils) were copolymerized by nitroxide-mediated polymerization to form epoxidized statistical and block copolymers with similar compositions (F GMA ∼0.8), which were further cross-linked by a bio-based diamine. Hybrid plate-like nanoparticles containing organophosphorus-titanium-silicon (PTS) with an average size of ∼130 nm and high decomposition temperature (485 °C) were synthesized via a hydrothermal reaction to serve as additives to simultaneously enhance the thermal and mechanical properties of the blend. Nanocomposites filled with PTS were prepared at different filler-loading levels (0.5, 2, 4 wt %). Transmission electron microscopy (TEM) of the cured block copolymer displayed reaction-induced macrophase-separated domains. TEM also showed an effective dispersion of PTS hybrids in the matrix without intense agglomeration. Thermogravimetric analysis at different heating rates revealed the activation energy of poly (GMA-stat-C13MA) at maximum decomposition increased from 143.5 to 327.2 kJ mol-1 with 4 wt % PTS. Decomposition temperature and char residue improved 12 °C and ∼7 wt %, respectively, and T g increased 12 °C by adding 4 wt % PTS. Targeting various PTS concentrations enabled tuning of the tensile modulus (up to 75%), tensile strength (up to 46%), and storage modulus in both glassy state (up to 59%) and rubbery plateau regions (up to 88%). Oscillatory frequency sweeps indicated that PTS makes the storage modulus frequency dependent, suggesting that the inclusion of the nanoparticles alters the relaxation of the surrounding matrix polymer.

1D and 2D hybrid polymers based on zinc phenylphosphates: synthesis, characterization and applications in electroactive materials

The synthesis, structure and properties of three hybrid polymers based on zinc arylphosphates are described in this study. Zinc bis(diphenylphosphate) (ZnDPhP) was obtained as needle-like crystals containing hexagonally packed, homochiral 1 ∞[Zn(DPhP)2/2] helical chains. The XRD and DSC studies revealed that upon heating, ZnDPhP undergoes a reversible thermal transition at ca. 160 °C with expansion mainly perpendicular to its c-axis. Zinc phenylphosphate hydrate (ZnMPhP-H) formed plate-like particles with an average thickness of less than 1 μm and much thinner nanolayers with a basal spacing of 15.5 Å. ZnMPhP-H was easily and reversibly dehydrated to its anhydrous form, ZnMPhP-A, which exhibited a somewhat larger basal spacing of 16.5 Å and the capacity for amine intercalation. The thermal decomposition of ZnDPhP or ZnMPhP-A began around 250 °C, resulting in the formation of solid mixtures of zinc phosphates and electron-conducting carbonaceous phases. The bulk electrical conductivities of the poly(vinylidene fluoride)-based composites containing the ZnDPhP pyrolyzates reached 0.1-0.2 S cm-1. Upon mixing with silicone oil, all the synthesized hybrid polymers formed fluids that exhibit significant negative electrorheological effects and have potential for application in electroresponsive smart materials. The application of an electric field during the crosslinking of such systems affected the viscoelastic properties of the resultant solid composites, while the cured systems showed rather small electrorheological effects.

Synthesis of Core-Shell Micro/Nanoparticles and Their Tribological Application: A Review

Owing to the diverse composition, adjustable performance, and synergistic effect among components, core–shell micro/nanoparticles have been widely applied in the field of tribology in recent years. The strong combination with the matrix and the good dispersion of reinforcing fillers in the composites could be achieved through the design of core–shell structural particles based on the reinforcing fillers. In addition, the performance of chemical mechanical polishing could be improved by optimizing the shell material coated on the abrasive surface. The physical and chemical state of the core–shell micro/nanoparticles played important effects on the friction and wear properties of materials. In this paper, the synthesis methods, the tribological applications (acted as solid/liquid lubricant additive, chemical mechanical polishing abrasives and basic units of lubricant matrix), and the functionary mechanisms of core–shell micro/nanoparticles were systematically reviewed, and the future development of core–shell micro/nanoparticles in tribology was also prospected.

Flame Retardation of Natural Rubber: Strategy and Recent Progress

Natural rubber (NR) as a kind of commercial polymer or engineering elastomer is widely used in tires, dampers, suspension elements, etc., because of its unique overall performance. For some NR products, their work environment is extremely harsh, facing a serious fire safety challenge. Accordingly, it is important and necessary to endow NR with flame retardancy via different strategies. Until now, different methods have been used to improve the flame retardancy of NR, mainly including intrinsic flame retardation through the incorporation of some flame-retarding units into polymer chains and additive-type flame retardation via adding some halogen or halogen-free flame retardants into NR matrix. For them, the synergistic flame-retarding action is usually applied to simultaneously enhance flame retardancy and mechanical properties, in which some synergistic flame retardants such as organo-montmorillonite (OMMT), carbon materials, halloysite nanotube (HNT), etc., are utilized to achieve the above-mentioned aim. The used flame-retarding units in polymer chains for intrinsic flame retardation mainly include phosphorus-containing small molecules, an unsaturated chemical bonds-containing structure, a cross-linking structure, etc.; flame retardants in additive-type flame retardation contain organic and inorganic flame retardants, such as magnesium hydroxide, aluminum hydroxide, ammonium polyphosphate, and so on. Concerning the flame retardation of NR, great progress has been made in the past work. To achieve the comprehensive understanding for the strategy and recent progress in the flame retardation of NR, we thoroughly analyze and discuss the past and current flame-retardant strategies and the obtained progress in the flame-retarding NR field in this review, and a brief prospect for the flame retardation of NR is also presented.

Polybenzoxazine Resins with Polyphosphazene Microspheres: Synthesis, Flame Retardancy, Mechanisms, and Applications

Polyphosphazene microspheres were fabricated by ultrasonic-assisted precipitation polymerization using 4,4'-(hexafluoroisopropylidene)diphenol, 4,4'-sulfonyldiphenol, 4,4-(9-fluorenylidene)diphenol, and phenolphthalein to obtain poly[4,4'-(hexafluoroisopropylidene)diphenol]phosphazene (PZAF), poly(4,4'- sulfonyldiphenol)phosphazene (PZS), poly[4,4'-(9-fluorenylidene)diphenol]phosphazene, and poly(phenolphthalein)phosphazene (PZPT) and were incorporated into polybenzoxazines (PBa) to obtain corresponding PZAF/PBa, PZS/PBa, fluorenyl polyphosphazene (PZFP)/PBa, and PZPT/PBa composites. Addition of 5 wt % of PZAF, PZS, PZFP, and PZPT microspheres improved the thermal stability and fire retardancy of PBa resin significantly. Notably, addition of PBa with 5% PZAF led to a 62.5% decrease in the peak heat release rate and 49.3% reduction in total heat release. The role of microspheres in the gas-phase flame-retardancy mechanism in the PBa matrix was studied. Dynamic mechanical analysis results demonstrated that the T _g of PBa flame-retardant composites was still around 210 °C compared to 221 °C of pure PBa. Hence, the synthesized PBa composites had potential applications as high flame-retardancy materials.

Facile synthesis of a novel transparent hyperbranched phosphorous/nitrogen-containing flame retardant and its application in reducing the fire hazard of epoxy resin

In this study, a novel hyperbranched phosphorus/nitrogen-containing flame retardant (HPNFR) was facilely synthesized via the transesterification reaction of dimethyl methylphosphonate and tris (2-hydroxyethyl) isocyanurate and characterized successfully by ¹H NMR and FTIR. The sample with 4 wt% HPNFR can achieve V-0 rating in UL-94 test and possess a LOI value as high as 34.5%. Conspicuous blowing-out effect was observed during the vertical burning test. TG results indicated that the presence of HPNFR significantly improved the thermal stability of EP thermosets. From cone test, THR, p-HRR, p-SPR and TSP values of HPNFR/EP composites were decreased in comparison to those of pure EP, revealing the reduced fire hazard of EP composites with HPNFR. SEM images of EP thermoset with 4 wt% of HPNFR after cone test exhibited compact and continuous char layers, while those of pure EP are fragmentary and broken. From TG-IR test, the yield of toxic CO and other pyrolysis products was significantly reduced, indicating a decrease in toxicity. Phosphorus-containing compounds were detected in gas phase, which verified the gaseous phase flame retardant effect of HPNFR. Besides, HPNFR would not significantly damage the transparence of EP thermosets, consequently reserved it's application value in some special fields.

Confined Dispersion of Zinc Hydroxystannate Nanoparticles into Layered Bimetallic Hydroxide Nanocapsules and Its Application in Flame-Retardant Epoxy Nanocomposites

In many fields, nanoparticles are frequently dispersed onto kinds of nanocarriers integrated into hybrid nanocomposites to acquire advanced performance. However, the nanoparticles usually tend to agglomerate on the surface, according to traditional synthetic methods. Besides, the exposed state of loaded nanoparticles and the weak adhesion with the supporters make them fall off during practical application, leading to "second agglomeration" of the nanoparticles and attenuated synergistic effects. In this work, we engineered layered bimetallic (Ni-Co) hydroxides (NCHs) into enclosed nanocages derived from metal organic frameworks (MOFs). Zinc hydroxystannate (ZHS) nanoparticles were selected to be confined dispersed within the hollow cavity of the three-dimensional nanocages. ZHS nanoparticles were tightly immobilized, monodispersing to form a novel multiyolk@shell nanostructure with NCH nanocages. To prove the effectiveness of this structural design, the as-synthesized hybrids ZHS@NCH were introduced into the epoxy matrix to inquiry its performance. Compared to neat ZHS, neat NCH, and physical mixture of ZHS and NCH, ZHS@NCH conferred better flame retardancy, thermal stability, and mechanical properties upon the epoxy nanocomposites. With the adding amount of 6 wt % ZHS@NCH, the UL-94 rating of the nanocomposite was V-0, and the peak of heat release rate value was reduced by 69.1%, while the mechanical properties were slightly influenced. The ingenious synthetic strategy gives insights into uniform distribution of nanoparticles within nanocapsules and enlightens the facile fabrication of multiyolk@shell nanomaterials.

Core-shell nanospheres to achieve ultralow friction polymer nanocomposites with superior mechanical properties

Core-shell nanospheres have been widely used in catalysis, batteries, medicine, etc. owing to their unique structural characteristics, which exhibit optimal performance and integrated functions of both the core and shell materials. To simultaneously achieve outstanding mechanical properties and remarkable lubrication properties in desirable polymer composites, core-shell nanospheres with polytetrafluoroethylene (PTFE) as the core and poly methyl methacrylate (PMMA) as the shell have been adopted as structural units to form bulk nanocomposites. We demonstrated that the mechanical and lubrication properties of the nanocomposites prepared using core-shell nanospheres as the continuous matrix were dramatically improved. Specifically, when compared with that of pure PTFE, the compressive strength of the PTFE@PMMA nanocomposite obviously increased up to one order of magnitude (from ∼9 to ∼90 MPa), the friction coefficient reduced to 25% (the lowest value was 0.03), and the wear rate decreased up to two orders of magnitude. Moreover, the mechanical and lubrication properties of the nanocomposites could be adjusted by changing the core-shell ratio, and an appropriate core-shell ratio was beneficial for achieving the desired comprehensive properties. It has been proposed that the properties, such as the confinement effect, improved dispersion capacity, etc., imparted by the core-shell structure effectively lead to high dispersion of the reinforcement phase, improvement of the binding force of the transfer film to the friction surface, and interruption of the wear process of the polymer composite.