A flame-retardant epoxy resin based on a reactive phosphorus-containing monomer of DODPP and its thermal and flame-retardant properties

A flame-retardant epoxy resin (EP) was synthesized based on a novel reactive phosphorus-containing monomer, 4-[(5,5-dimethyl-2-oxide-1,3,2-dioxaphosphorinan-4-yl)oxy]-phenol (DODPP), and its structures were characterized by FTIR, ¹H NMR and ³¹P NMR spectra. The DODPP-EP₃/LWPA (low molecular weight polyamide), which contains 2.5% phosphorus, can reach UL-94 V-0 rating and a limiting oxygen index (LOI) value of 30.2%. The thermal properties and burning behaviours of cured epoxy resins were investigated by differential scanning calorimeter (DSC), thermogravimetry (TG), LOI, UL-94 tests and cone calorimetry. The morphologies of residues of cured epoxy resins were investigated by scanning electron microscopy (SEM). DSC shows that the glass-transition temperatures of cured epoxy resins decrease with increasing phosphorus content. TGA shows that the onset decomposition temperatures and the maximum-rate decomposition temperatures decrease, while char yields increase, with the increase of phosphorus content. The data from the cone calorimeter tests give the evidence that heat release rate (HRR), peak heat release rate (PHRR), average heat release rate (Av-HRR), average mass loss rate (Av-MLR) and the fire growth rate index (FIGRA) decrease significantly for DODPP-EP₃/LWPA. SEM shows that the DODPP-EP₃/LWPA forms lacunaris and compact charred layers which inhibit the transmission of heat during combustion.     

Synthesis and Property of Flame Retardant Epoxy Resins Modified with 2-（Diphenylphosphinyl）-l,4-benzenediol

2-（Diphenylphosphinyl）-1,4-benzenediol（DPO-HQ） was synthesized by the reaction of diphenylphos- phine oxide（DPO） with 1,4-benzoquinone（BQ）, and characterized by Fourier transform infrared（FTIR）, and nuclear magnetic resonance（1H NMR, 13C NMR, 31p NMR） spectrometries. The thermal stability of DPO-HQ was investi- gated by thermogravimetric analysis（TGA）. Flame retardant epoxy resin was synthesized based on DPO-HQ. The thermal properties and burning performance of cured epoxy resins were measured by differential scanning calorime- try（DSC）, thermogravimetric analysis（TGA）, limited oxygen index（LOI） and vertical burning test（UL-94V）. The morphologies of cured epoxy resins after combustion were investigated by scanning electron microscopy（SEM） and electron probe microanalysis（EPMA）. Moreover, the thermal stability（both in air and in N2） of DPO-HQ and its cured epoxy resin was compared with that of 10-（2,5-dihydroxyphenyl）-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10- oxide（DOPO-HQ） and its cured epoxy resin. The thermal stability of DPO-HQ is comparable with that of DOPO-HQ, while the thermal stability of cured epoxy resin based on DPO-HQ is better than that based on DOPO-HQ.     

Synthesis,characterization, thermal,and flame retardant properties of phosphate-based epoxy resins

A new phosphorus-containing oxirane bis-glycidyl phenylphosphate (BGPP), and a diamine, bis(4-aminophenyl)phenylphosphate (BAPP), were synthesized. Both of these two phosphorus-containing compounds lead to phosphate-containing epoxy resin via curing reaction. The kinetics of the curing reaction of BGPP with various curing agents, including BAPP, were studied. The introduction of electron-withdrawing group into the compounds increases the BGPP and decreases the BAPP reactivity in the curing reaction. The thermal and the weight loss behavior of the cured epoxy resins were studied by TGA. High char yields (32–52%) as well as high limiting oxygen index (LOI) values (34–49) of these phosphorylated resins were found, confirming the usefulness of these phosphorus-containing epoxy resins as flame retardants. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35: 565–574, 1997.     

含磷有机硅杂化环氧树脂固化体系性能研究

通过磷酸与γ-环氧丙氧基三甲氧基硅烷反应得到含磷有机硅氧烷,并加入到环氧树脂/4,4'-二氨基二苯基甲烷体系中混合,通过溶胶-凝胶的方法制备了含磷有机硅杂化环氧树脂固化物.对固化体系进行了玻璃化转变温度、热失重、阻燃、拉伸强度、冲击强度测试分析.结果表明,该固化体系的阻燃性得到提高,极限氧指数在25.8～29.3,玻璃化转变温度得到提高,在161～179℃;虽然初始分解温度比纯环氧树脂固化物低,但800℃残炭率可以达到26.5%,提高了36%;拉伸强度得到提高,在71～94 MPa,冲击强度可以达到14.36 kJ/m2,提高了14%.该固化体系具有较好的阻燃性能和热性能,同时具有较好的力学性能.     

Thermal and flame retardant properties of epoxy resin cured by a novel phosphorus-containing 4,4′-bisphenol novolac curing agent

A novel flame retardant curing agent for epoxy resin (EP), i.e., a DOPO (9,10-dihydro-9-oxa-10-phosphaphenan-threne-10-oxide)-containing 4,4'-bisphenol novolac (BIP-DOPO) was synthesized and characterized by Fourier transform infrared (FTIR), ¹H NMR, ³¹P NMR spectroscopy, and gel permeation chromatography. The epoxy resin cured by BIP-DOPO itself or its mixture with a commonly used bisphenol A-formaldehyde novolac resin (NPEH720) was prepared. The flame retardancy of the cured EP thermosets were studied by limiting oxygen index (LOI), UL 94 and cone calorimeter test (CCT), and the thermal properties by thermal gravimetric analysis (TGA) and differential scanning calorimetry (DSC). The results show that the cured epoxy resin EPNP/BI/3/1, which contains 2.2% phosphorus, possesses a value of 26.2% and achieves the UL 94 V-0 rating. The data from cone calorimeter test demonstrated that the peak release rate, average heat release rate, total heat release decline sharply for the flame retarded epoxy resins, compared with those of pure ones. DSC results show that the glass-transition temperatures of cured epoxy resins decrease with increasing phosphorus content. TGA indicates that the incorporation of BIP-DOPO promotes the decomposition of epoxy resin matrix ahead of time and leads to higher char yield. The surface morphological structures of the char residues reveal that the introduction of BIP-DOPO benefits to the formation of a continuous and solid char layer on the epoxy resin material surface during combustion.     

Preparation,flame retardancy,and thermal degradation of epoxy thermosets modified with phosphorous/nitrogen‐containing glycidyl derivative

Phosphorus/nitrogen‐containing advanced epoxy resins were obtained by chain‐extension of the diglycidyl ether of bisphenol‐A epoxy (DGEBA) resin with phosphorus‐modified triglycidyl isocyanurate (TGICP). The structure of TGICP was characterized by Fourier transform infrared spectroscopy (FTIR) and nuclear magnetic resonance (NMR). Differential scanning calorimetry revealed that the EP/TGICP composites possessed higher glass transition temperatures than that of phosphorus free EP. The thermal stability and flame retardant properties of the epoxy resin/TGICP systems were investigated by thermogravimetric analysis (TGA), limiting oxygen index (LOI), and vertical burning test (UL‐94) test. When the TGICP content was 10 wt%, the LOI value of epoxy resin system was as high as 35.0% and it can obtain the V‐0 grade in UL‐94 protocol. From microscale combustion calorimetry (MCC) measurement, it was found that the addition of TGICP reduced the value of peak heat release rate and total heat release. The thermal degradation process of EP and EP/TGICP composite was monitored by real time FTIR. Moreover, scanning electron microscopy (SEM) and X‐ray photoelectron spectroscopy (XPS) were used to explore the morphology and chemical components of the char residues. Copyright © 2010 John Wiley & Sons, Ltd.     

阻燃型含磷环氧树脂体系的研究进展

将磷导入环氧树脂体系而赋予其阻燃性能是目前热门的研究课题。本文简述了含磷阻燃剂的阻燃机理，详细讨论了含磷阻燃环氧的类型及固化物的阻燃特性，以及磷和氮、硅等元素的协同效应。     

含季戊四醇磷酸酯阻燃剂的合成与表征

采用1-氧代-4-羟甲基-2,6,7-三氧杂-1-磷杂双环[2.2.2]辛烷(PEPA)、三氯氧磷、双酚A和双酚S为反应物,合成了两个新型添加型阻燃剂:双酚A双[二(1-氧代-1-磷杂-2,6,7-三氧杂双环辛烷-4-亚甲基)]磷酸酯(BAPP)和双酚S双[二(1-氧代-1-磷杂-2,6,7-三氧杂双环辛烷-4-亚甲基)]磷酸酯(BSPP),通过元素分析、FT-IR和1H NMR等表征了标题化合物的结构,结果表明,所合成的标题化合物的结构与预期一致。热失重分析结果证明,BAPP和BSPP质量损失5%(wt)时的温度分别为343.6℃和352.3℃,600℃残余量分别达46.6%和55.5%,具有较高的热稳定性和结炭性能。阻燃性能实验证明,E-51环氧树脂中分别添加质量分数为18.2%(wt)的BAPP和BSPP时,极限氧指数分别为32.2%和31.8%,均能达到UL 94 V-0级。     

Synthesis and properties of phosphorus-containing epoxy resins by novel method

Novel phosphorus-containing epoxy resins (1–3% phosphorus content) were synthesized by the reaction of 9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide (DOPO) and the diglycidyl ether of bisphenol A and then cured with 4,4′-diaminodiphenyl sulfone or phenol novolac. Differential scanning calorimetry, high performance liquid chromatography, and epoxide equivalent weight titration were used to trace the reaction between the DOPO and the epoxy. The thermal stability and flame retardancy were checked by thermal gravimetric analysis, the limiting oxygen index, and the UL-94 vertical test. The glass transitions were measured by dynamic mechanical analysis. The relation between these properties (thermal stability, flame retardancy, and glass transition) and the DOPO contents (phosphorus content) were discussed. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 3903–3909, 1999     

A bio-based epoxy resin derived from p-hydroxycinnamic acid with high mechanical properties and flame retardancy

Recent advances in epoxy resins have been forward to achieving high mechanical performance, thermal stability, and flame retardancy. However, seeking sustainable bio-based epoxy precursors and avoiding introduction of additional flame-retardant agents are still of increasing demand. Here we report the synthesis of p-hydroxycinnamic acid-derived epoxy monomer (HCA-EP) via a simple one-step reaction, and the HCA-EP can be cured with 4,4′-diaminodiphenylmethane (DDM) to prepare epoxy resins. Compared with the typical petroleum-based epoxy resin, bisphenol A epoxy resin, the HCA-EP-DDM shows a relatively high glass transition temperature (192.9 °C) and impressive mechanical properties (tensile strength of 98.3 MPa and flexural strength of 158.9 MPa). Furthermore, the HCA-EP-DDM passes the V-1 flammability rating in UL-94 test and presents the limiting oxygen index of 32.6%. Notably, its char yield is as high as 31.6% under N₂, and the peak heat rate release is 60% lower than that of bisphenol A epoxy resin. Such findings provide a simple way of using p-hydroxycinnamic acid instead of bisphenol A to construct high-performance bio-based thermosets.     

Preparation of phosphorus‐containing phenolic resin and its application in epoxy resin as a curing agent and flame retardant

For the sake of improving the flame retardancy of epoxy resin (EP), a novel phosphorus‐containing phenolic resin (PPR) synthesized in our group instead of conventional phenolic resin (PR) was used to cure EP in the present research. The curing processes and the corresponding crosslinking structure and mechanical performance were investigated by differential scanning calorimeter and dynamic mechanical thermal analysis. Because of the introduction of flame‐retarding elements including P and Si, PPR exhibited higher charring capacity in the condensed phase, which is helpful to construct a char layer of higher quality. Correspondingly, PPR‐cured EP displayed remarkably improved flame retardance as compared to conventional PR‐cured EP through the related evaluations including limiting oxygen index, vertical burning test, and microscale combustion colorimeter. As a multifunction agent, it is believable that PPR possesses potential commercial value to prepare flame‐retardant EP with high performance.     

Development of novel phosphorus‐containing epoxy resins from renewable resources

Novel biobased epoxy resins were prepared from two fatty acid derivatives; epoxidized 10‐undecenoyl triglyceride and epoxidized methyl 3,4,5‐tris(10‐undecenoyloxy)benzoate, with 4,4′‐diaminodiphenylmethane as a crosslinking agent. The flame retardancy of these epoxy resins was improved by the addition of 10‐[2′, 5′‐bis(9‐oxiranyl‐nonayloxy)phenyl]‐9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide and by crosslinking with a phosphorus‐containing curing agent, bis(m‐aminophenyl)methylphosphine oxide. The thermal, thermomechanical, and flame‐retardant properties of the cured materials were measured with differential scanning calorimetry, thermogravimetric analysis, dynamic mechanical analysis, and the limiting oxygen index. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 6717–6727, 2006     

Flame retardant epoxy polymers based on all phosphorus-containing components

A phosphorus-containing epoxy resin, bis(3-t-butyl-4-glycidyloxyphenyl-2,4-di-t-butylphenyl)resorcinol diphosphate, was synthesized and subsequently cured with non-phosphorus containing amines, and/or novel phosphorus-containing aromatic or polyoxyalkylene amines. Chemical structures of these materials were characterized with FTIR, NMR, elemental analysis, and amine titration. The introduction of soft -P-O- linkage, polyoxyalkyene, or hard aromatic group into the backbones of the synthesized phosphorus-containing amines provides epoxy polymers with high phosphorus contents and tailored flexibility. Thermal analysis of differential scanning calorimeter and thermal gravimetric analysis (TGA) reveals that these resulted epoxy polymers possess moderate T_gs and thermal stability. Furthermore, high char yields in TGA analysis and high limited oxygen index values indicate that these phosphorus-containing epoxy polymers possess excellent flame retardant properties.     

Synthesis of a novel phosphorus‐containing curing agent and its effects on the flame retardancy,thermal degradation and moisture resistance of epoxy resins

A novel phosphorus‐containing compound diphenyl‐(1, 2‐dicarboxylethyl)‐phosphine oxide defined as DPDCEPO was synthesized and used as a flame retardant curing agent for epoxy resins (EP). The chemical structure of the prepared DPDCEPO was well characterized by Fourier transform infrared spectroscopy, and ¹H, ¹³C and ³¹P nuclear magnetic resonance. The DPDCEPO was mixed with curing agent of phthalic anhydride (PA) with various weight ratios into epoxy resins to prepare flame retardant EP thermosets. The flame retardant properties, combustion behavior and thermal analysis of the EP thermosets were respectively investigated by limiting oxygen index (LOI), vertical burning tests (UL‐94), cone calorimeter measurement, dynamic mechanical thermal analysis and thermogravimetric analysis (TGA) tests. The surface morphologies and chemical compositions of the char residues for EP thermosets were respectively investigated by scanning electron microscopy and X‐ray photoelectron spectroscopy (XPS). The water resistant properties of the cured EP were evaluated by putting the samples into distilled water at 70°C for 168 hr. The results revealed that the EP/20 wt% DPDCEPO/80 wt% PA thermosets successfully passed UL‐94 V‐0 flammability rating and the LOI value was as high as 33.2%. The cone test results revealed that the incorporation of DPDCEPO effectively reduced the combustion parameters of the epoxy resin thermosets, such as heat release rate and total heat release. The dynamic mechanical thermal analysis test demonstrated that the glass transition temperature (Tg) decreased with the increase of DPDCEPO content. The TGA results indicated that the incorporation of DPDCEPO promoted the decomposition of epoxy resin matrix ahead of time and led to a higher char yield and thermal stability at high temperatures. The surface morphological structures and analysis of the XPS of the char residues of EP thermosets revealed that the introduction of DPDCEPO benefited the formation of a sufficient, compact and homogeneous char layer with rich flame retardant elements on the epoxy resin material surface during combustion. The mechanical properties and water resistance of the cured epoxy resins were also measured. After water resistance tests, the EP/20 wt% DPDCEPO/80 wt% PA thermosets retained excellent flame retardancy, and the moisture adsorption of the EP thermosets decreased with the increase of DPDCEPO content in EP thermosets because of the existence of the P–C bonds and the rigid aromatic hydrophobic structure in DPDCEPO. Copyright © 2015 John Wiley & Sons, Ltd.     

Synthesis and characterization of polybenzoxazine containing phosphorus

The novel benzoxazine monomer containing phosphorus has been synthesized based on multifunctional amine route from bis(4-aminophenyl)phenylphosphate,p-cresol and formaldehyde.Subsequently,the benzoxazine monomer was thermo-cured into polybenzoxazine containing phosphorus.The chemical structures were identified by nuclear magnetic resonance(NMR),Fourier transform infrared spectroscopy(FT-IR).The curing reaction was monitored by differential scanning calorimetry(DSC) and FT-IR.The thermal and flame-retardant properties of obtained polybenzoxazine were evaluated by dynamic mechanical thermal analysis(DMA),thermal gravimetric analysis(TGA) and oxygen index meter, respectively.The results show that the novel polybenzoxazine has high limiting oxygen index(38.1) and glass transition temperature(232℃).     

A Well-Defined Cyclotriphosphazene-Based Epoxy Monomer and Its Application as A Novel Epoxy Resin: Synthesis,Curing Behaviors,and Flame Retardancy

Abstract

A novel cyclotriphosphazene-based epoxy monomer, hexa-[4-(glycidyloxycarbonyl) phenoxy]cyclotriphosphazene (HGCP), was synthesized via a four-step synthetic route, and fully characterized by ¹H, ¹³C, and ³¹P NMR spectroscopy, high-resolution mass spectrometry, and elemental analysis. Thermosetting systems based on HGCP with three curing agents, for example, 4,4′-diaminodiphenylsulfone (DDS), 4,4′-diaminodiphenylmethane (DDM), and dicyandiamide (DICY), were used for making a comparison of their thermal curing behaviors. The curing behaviors were measured by differential scanning calorimetry. Moreover, flame retardancy of HGCP thermosetting systems was estimated by Limiting Oxygen Index (LOI) and Vertical Burning Test (UL-94). The resulting HGCP thermosetting systems exhibited better flame retardancy than the common epoxy resins diglycidyl ether of bisphenol A (DGEBA) and the regular brominated bisphenol A epoxy resin (TBBA) cured by DDS, respectively. When HGCP was cured by DDS, its thermosetting system gave the most char residues, met the UL-94 V-0 classification, and had a limiting oxygen index value greater than 35.     

A flame‐retardant phosphate and cyclotriphosphazene‐containing epoxy resin: Synthesis and properties

A novel flame‐retardant epoxy resin, (4‐diethoxyphosphoryloxyphenoxy)(4‐glycidoxyphenoxy)cyclotriphosphazene (PPCTP), was prepared by the reaction of epichlorohydrin with (4‐diethoxyphosphoryloxyphenoxy)(4‐hydroxyphenoxy)cyclotriphosphazene and was characterized by Fourier transform infrared, ³¹P NMR, and ¹H NMR analyses. The epoxy resin was further cured with diamine curing agents, 4,4′‐diaminodiphenylmethane (DDM), 4,4′‐diaminodiphenylsulfone (DDS), dicyanodiamide (DICY), and 3,4′‐oxydianiline (ODA), to obtain the corresponding epoxy polymers. The curing reactions of the PPCTP resin with the diamines were studied by differential scanning calorimetry. The reactivities of the four curing agents toward PPCTP were in the following order: DDM > ODA > DICY > DDS. In addition, the thermal properties of the cured epoxy polymers were studied by thermogravimetric analysis, and the flame retardancies were estimated by measurement of the limiting oxygen index (LOI). Compared to a corresponding Epon 828‐based epoxy polymer, the PPCTP‐based epoxy polymers showed lower weight‐loss temperatures, higher char yields, and higher LOI values, indicating that the epoxy resin prepared could be useful as a flame retardant. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 972–981, 2000     

Synthesis of novel boron‐containing epoxy–novolac resins and properties of cured products

Epoxy–novolac resins were synthesized by modifying a commercial novolac resin with epichlorohydrin. These epoxy–novolac resins were characterized and further modified with different contents of bis(benzo‐1,3,2‐dioxa‐borolanyl)oxide or bis(4,4,5,5‐tetramethyl‐1,3,2‐dioxa‐borolanyl)oxide. The boron‐containing epoxy–novolac resins were autocatalytically crosslinked or crosslinked with BF₃MEA and their thermal stability and flame retardancy were determined by thermogravimetric analysis and limiting oxygen index (LOI) values. These LOI values for the bis(benzo‐1,3,2‐dioxa‐borolanyl)oxide derivatives were higher than the boron‐free novolac resins, which shows the benefit of the presence of boron. To test the role of boron in the enhancement of flammability, scanning electronic microscopy and energy‐dispersive X‐ray spectroscopy images were made. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 6332–6344, 2006     

Study on liquid oxygen compatibility of bromine‐containing epoxy resins for the application in liquid oxygen tank

The liquid oxygen compatible epoxy resin was obtained by the polycondensation between tetrabromobisphenol A and neat epoxy resins. The results of liquid oxygen impact test indicated that the synthetic epoxy resins were compatible with liquid oxygen. The relationship between impact reaction sensitivity (IRS) and flame retardancy were studied by liquid oxygen impact test and limiting oxygen index test. The results showed that the flame‐retardant modification of epoxy resin was valuable to reduce the IRS. The thermal gravimetric analysis results indicated that the Br · radical was quickly released in relatively low temperature (approximately 370°C) for compatible epoxy resin. The Br · radical was a key factor to promote the epoxy resin compatible with the liquid oxygen. The X‐ray photoelectron spectroscopy was used to survey the distribution of functional groups on the surface of samples before and after impact. The results showed that the oxidation reaction and carbonization process may occur on the surface of samples after impact. The liquid oxygen compatibility mechanism is proposed in this paper. The bromine‐containing epoxy resin has the potential to be the material used in liquid oxygen tank. Copyright © 2015 John Wiley & Sons, Ltd.     

Thermal and physical properties of flame-retardant epoxy resins containing 2-(6-oxido-6H-dibenz〈c,e〉〈1,2〉oxaphosphorin-6-yl)-1,4-naphthalenediol and cured with dicyanate ester

2-(6-oxido-6H-dibenz(c,e)(1,2)oxaphosphorin-6-yl)-1,4-naphthalenediol (DOPONQ) was prepared by the addition reaction of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) with 1,4-naphthoquinone. The phosphorus-containing diol (DOPONQ) was used as a reactive flame retardant by an advancement reaction with the diglycidyl ether of bisphenol-A epoxy (DGEBA) resin at various stoichiometric ratios. DOPONQ-containing advanced epoxy was separately cured with various dicyanate esters to form flame-retardant epoxy/cyanate ester systems. The effect of the phosphorus content and dicyanate ester structure on the curing characteristic, glass transition temperature, dimensional stability, thermal stability, flame retardancy, and dielectric property was studied and compared with that of the control advanced bisphenol-A epoxy system. The DOPONQ-containing epoxy/cyanate ester systems exhibited higher glass transition temperatures as well as better thermal dimensional and thermal degradation stabilities. The flame retardancy of the phosphorus-containing epoxy/dicyanate ester system increased with the phosphorus content, and a UL-94 V-0 rating could be achieved with a phosphorus content as low as 2.1%.