Flame Retardant Polypropylene Composites with Low Densities

Synergistic Effect of Nano-Silica and Intumescent Flame Retardant on the Fire Reaction Properties of Polypropylene Composites

Silica nanoparticles (nano-silica) were used as synergistic agents with ammonium polyphosphate (APP) and pentaerythritol (PER) to enhance flame retardancy of polypropylene (PP) in this research. The composites were prepared using a melt-mixing method. The influences of nano-silica on the fire performance of composites were thoroughly discussed, which promotes understanding of nano-silica on the flame-retardant performance of polypropylene composite. Scanning electron microscope (SEM) and energy-dispersive spectrometer (EDS) results indicated that the nano-silica with a diameter of about 95 ± 3.9 nm were dispersed favorably in the composite matrix, which might elevate its synergistic effect with intumescent flame retardant and improve the flame retardancy of polypropylene composite. The synergistic effects between nano-silica and intumescent flame retardant on PP composites were studied using the limiting oxygen index (LOI), UL-94 test, and cone calorimeter test (CCT). The total amount of flame retardant was maintained at 30%. When the dosage of nano-silica was 1 wt.%, the LOI value of PP/IFR/Si1.0 composite reached 27.3% and its UL-94 classification reached V-1. Based on the parameters of the CCT, the introduction of nano-silica induced composites with depressed heat release rate (HRR) and peak heat release rate (PHRR). The PHRR of PP/IFR/Si0.5 was only 295.8 kW/m², which was 17% lower than that of PP/IFR. Moreover, the time to PHRR of PP/IFR/Si0.5 was delayed to 396 s, which was about 36 s later than that without nano-silica. EDS was used to quantitatively analyze the distribution of silica in charred residue. The EDS results indicated that the silica tended to accumulate on the surface during the fire. The surface accumulation characteristic of silica endows it with the enhanced flame-retardant properties of polypropylene composite at a very small dosage (as low as 1 wt.%).

Physical Properties of Glass-Fibre-Reinforced Polymer Filled with Alumina Trihydrate and Calcium Carbonate

Gutters made of glass-fibre-reinforced polymer (GFRP) are usually produced with a three-millimetre thickness. The fillers are mixed into unsaturated polyester (UP) resin, which is intended to make the composite material more affordable. This study aims to examine the effects of the addition of alumina trihydrate (ATH), calcium carbonate (CC), and a mixture of ATH and CC of 15 and 30 parts per hundredweight of resins (PHR) on the material properties of the three-millimetre-thick three-layered GFRP composites. The properties observed included physical properties, namely, specific gravity and water absorption, chemical properties such as burning rate, and mechanical properties such as hardness, flexural strength, and toughness. The effects of the fillers on the voids and interfacial bond between the reinforcing fibre and matrix were analysed using the flexural fracture observation through scanning electron microscopy (SEM). The results showed that the addition of fillers into the UP resin led to an increase in the density, hardness, flexural strength, modulus of elasticity, and toughness but a decrease in water absorption and burning rate in a horizontal position. This information can be helpful for manufacturers of gutters made of GFRP in selecting the appropriate constituent materials while considering the technical and economic properties.

Clays as Inhibitors of Polyurethane Foams' Flammability

Polyurethanes are a very important group of polymers with an extensive range of applications in different branches of industry. In the form of foams, they are mainly used in bedding, furniture, building, construction, and automotive sectors. Due to human safety reasons, these applications require an appropriate level of flame retardance, often required by various law regulations. Nevertheless, without the proper modifications, polyurethane foams are easily ignitable, highly flammable, and generate an enormous amount of smoke during combustion. Therefore, proper modifications or additives should be introduced to reduce their flammability. Except for the most popular phosphorus-, halogen-, or nitrogen-containing flame retardants, promising results were noted for the application of clays. Due to their small particle size and flake-like shape, they induce a "labyrinth effect" inside the foam, resulting in the delay of decomposition onset, reduction of smoke generation, and inhibition of heat, gas, and mass transfer. Moreover, clays can be easily modified with different organic compounds or used along with conventional flame retardants. Such an approach may often result in the synergy effect, which provides the exceptional reduction of foams' flammability. This paper summarizes the literature reports related to the applications of clays in the reduction of polyurethane foams' flammability, either by their incorporation as a nanofiller or by preparation of coatings.

Polycarbonate/Sulfonamide Composites with Ultralow Contents of Halogen-Free Flame Retardant and Desirable Compatibility

A novel halogen-free flame retardant containing sulfonamide, 1,3,5,7-tetrakis (phenyl-4-sulfonamide) adamantane (FRSN) was synthesized and used for improving the flame retardancy of largely used polycarbonate (PC). The flame-retardant properties of the composites with incorporation of varied amounts of FRSN were analyzed by techniques including limited oxygen index, UL 94 vertical burning, and cone calorimeter tests. The new FR system with sulfur and nitrogen elements showed effective improvements in PC's flame retardancy: the LOI value of the modified PC increased significantly, smoke emission suppressed, and UL 94 V-0 achieved. Typically, the composite with only 0.08 wt% of FRSN added (an ultralow content) can increase the limiting oxygen index (LOI) value to 33.7% and classified as UL 94 V-0 rating. Furthermore, the mechanical properties and SEM morphology indicated that the FRSN has very good compatibility with PC matrix, which, in turn, is beneficial to the property enhancement. Finally, the analysis of sample residues after burning tests showed that a high portion of char was formed, contributing to the PC burning protection. This synthesized flame retardant provides a new way of improving PC's flame retardancy and its mechanical property.

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.

Synthesis and Application of H-ZSM-5 Zeolites with Different Levels of Acidity as Synergistic Agents in Flame Retardant Polymeric Materials

Several studies show a synergistic effect between intumescent formulations and aluminosilicates, such as zeolites and clays, but little is known about the effect of acidity of these additives on the synergistic action. In this work, H-ZSM-5 zeolite was submitted to desilication treatments for 30 min and for 2 h, and silicalite-1 was synthesized. The objective was to obtain samples of equivalent crystalline structure, but with different amounts of acid sites, in order to evaluate the effect of acid concentration of H-ZSM-5 zeolites on the synergistic action with an intumescent formulation composed by ammonium polyphosphate and pentaerythritol in polypropylene. H-ZSM-5 zeolites and silicalite were characterized by X-ray diffraction, nitrogen adsorption analysis and temperature-programmed desorption of ammonia. The desilication produced H-ZSM-5 zeolites with similar volumes of mesopores in both treatments, but the zeolite resulting from 2 h of desilication presented a higher concentration of acid sites than the zeolite from 30 min. The flame-retardant properties were evaluated by UL-94 classification, limiting oxygen index, glow-wire, thermogravimetric analysis and heating microscopy. The results showed that increasing the concentration and accessibility of the acid sites of H-ZSM-5 zeolites the flame-retardant properties of the studied composites improved. It is suggested that the increase of acid site concentration positively influences the catalysis of the reaction between ammonium polyphosphate and pentaerythritol, favoring the production of the precursors of the intumescent layer.

Nanoreinforcements of Two-Dimensional Nanomaterials for Flame Retardant Polymeric Composites: An Overview

Polymer materials are ubiquitous in daily life. While polymers are often convenient and helpful, their properties often obscure the fire hazards they may pose. Therefore, it is of great significance in terms of safety to study the flame retardant properties of polymers while still maintaining their optimal performance. Current literature shows that although traditional flame retardants can satisfy the requirements of polymer flame retardancy, due to increases in product requirements in industry, including requirements for durability, mechanical properties, and environmental friendliness, it is imperative to develop a new generation of flame retardants. In recent years, the preparation of modified two-dimensional nanomaterials as flame retardants has attracted wide attention in the field. Due to their unique layered structures, two-dimensional nanomaterials can generally improve the mechanical properties of polymers via uniform dispersion, and they can form effective physical barriers in a matrix to improve the thermal stability of polymers. For polymer applications in specialized fields, different two-dimensional nanomaterials have potential conductivity, high thermal conductivity, catalytic activity, and antiultraviolet abilities, which can meet the flame retardant requirements of polymers and allow their use in specific applications. In this review, the current research status of two-dimensional nanomaterials as flame retardants is discussed, as well as a mechanism of how they can be applied for reducing the flammability of polymers.