The synergistic flame‐retardant effect of O‐MMT on the intumescent flame‐retardant PP/CA/APP systems

The flame retardancy of a novel intumescent flame‐retardant polypropylene (IFR‐PP) system, which was composed of a charring agent (CA), ammonium polyphosphate (APP), and polypropylene (PP), could be enhanced significantly by adding a small amount (1.0 wt%) of an organic montmorillonite (O‐MMT). The synergistic flame‐retardant effect was studied systematically. The thermal stability and combustion behavior of the flame‐retarded PP were also investigated by thermogravimetric analysis (TGA), limiting oxygen index (LOI), vertical burning test (UL‐94), scanning electronic microscopy (SEM), and cone calorimeter test (CCT). TGA results demonstrated that the onset decomposition temperatures of IFR‐PP samples, with or without O‐MMT, were higher than that of neat PP. Compared with IFR‐PP, the LOI value of IFR‐PP containing 1.0 wt% O‐MMT was increased from 30.8 to 33.0, and the UL‐94 rating was also enhanced to V‐0 from V‐1 when the total loading of flame retardant was the same. The cone calorimeter results showed that the IFR‐PP with 1.0 wt% of O‐MMT had the lowest heat release rate (HRR), total heat release (THR), total smoke production (TSP), CO production (COP), CO₂ production (CO₂P), and mass loss (ML) of all the studied IFR‐PP samples, with or without O‐MMT. All these results indicated that O‐MMT had a significantly synergistic effect on the flame‐retardancy of IFR‐PP at a low content of O‐MMT. Copyright © 2009 John Wiley & Sons, Ltd.     

Microencapsulation of ammonium polyphosphate with hydroxyl silicone oil and its flame retardance in thermoplastic polyurethane

Microencapsulated ammonium polyphosphate (MAPP) is prepared using hydroxyl silicone oil by in situ polymerization and characterized by XPS. Microencapsulation gives MAPP better water resistance and flame retardance compared with APP in thermoplastic polyurethane (TPU). Thermal stability and fire resistance behavior have been analyzed and compared. The LOI value of the TPU/MAPP composite is higher than that of the TPU/APP composite. The UL 94 rating of the TPU/MAPP composite is V-0 at the 20 wt% additive level, whereas TPU/APP gives V-2 rating at the same loading level. The water resistant properties of the TPU composites are studied. Results of the cone calorimeter and microscale combustion calorimeter experiment show that MAPP is an effective flame retardant in TPU compared with APP.     

Novel flame retardancy effects of DOPO-POSS on epoxy resins

A series of flame retarded epoxy resins (EP) was prepared with a novel polyhedral oligomeric silsesquioxane containing 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO-POSS). The flame retardancy of these EPs was tested by the LOI, UL-94, which indicates that DOPO-POSS has meaningful effects on the flame retardancy of EP composites. 2.5 wt.% DOPO-POSS incorporation into epoxy resin (EP-2.5), results in a LOI value 30.2 and UL-94 V-1 (t₁ = 8 s and t₂ = 3 s) rating. Moreover, self-extinguishing effect through the pyrolytic gases spurt is observed in UL-94 test for the EP-2.5. The pyrolytic gases and thermal stability of epoxy resins with and without DOPO-POSS were detected by TGA-FTIR under air atmosphere. Releases of gaseous species are found to be similar for the pure EP and EP-2.5. The details of fire behaviour, such as TTI, HRR, p-HRR, TSR, SEA, COPR, CO₂PR, and TML, were tested by cone calorimeter. It is notable that 2.5 wt.% DOPO-POSS could make COPR and CO₂PR reach a maximum, which could explain the blowing-out extinguishing effect.     

Preparation and Characterization of Core/Shell-like Intumescent Flame Retardant and its Application in Polypropylene

With a shell of starch-melamine-formaldehyde (SMF) resin, core/shell-like ammonium polyphosphate (SMFAPP) is prepared by in situ polymerization, and is characterized by SEM, FTIR and XPS. The shell leads SMFAPP a high water resistance and flame retardance compared with APP in polypropylene (PP). The flame retardant action of SMFAPP and APP in PP are studied using LOI, UL 94 test and cone calorimeter, and their thermal stability is evaluated by TG. The flame retardancy and water resistance of the PP/SMFAPP composite at the same loading is better than that of the PP/APP composite. UL 94 ratings of PP/SMFAPP can reach V-0 at 30 wt% loading. The flame retardant mechanism of SMFAPP was studied by dynamic FTIR, TG and cone calorimeter, etc.     

The non-halogen flame retardant epoxy resin based on a novel compound with phosphaphenanthrene and cyclotriphosphazene double functional groups

A novel flame retardant additive hexa-(phosphaphenanthrene -hydroxyl-methyl-phenoxyl)-cyclotriphosphazene (HAP-DOPO) with phosphazene and phosphaphenanthrene double functional groups has been synthesized from hexa-chloro-cyclotriphosphazene, 4-hydroxy-benzaldehyde and 9,10-dihydro-9-oxa-10- phosphaphenanthrene 10-oxide(DOPO). The structure of HAP-DOPO was characterized by Fourier transformed infrared (FT-IR) spectroscopy and ¹H nuclear magnetic resonance (¹H NMR) and ³¹P nuclear magnetic resonance (³¹P NMR). The additive HAP-DOPO was blended into diglycidyl ether of bisphenol-A (DGEBA) to prepare flame retardant epoxy resins. The flame retardant properties and thermal properties of the epoxy resins cured by 4, 4′-Diamino-diphenyl sulfone (DDS) were investigated from the differential scanning calorimeter (DSC), the thermogravimetric analysis (TGA), UL94 test, the limiting oxygen index (LOI) test and Cone calorimeter. Compared to traditional DOPO-DGEBA and ODOPB-DGEBA thermosets, the HAP-DOPO/DGEBA thermosets have higher T_gs at the same UL94 V-0 flammability rating for their higher crosslinking density and have higher char yield and lower pk-HRR at same 1.2 wt.% phosphorus content which confirm that HAP-DOPO has higher flame retardant efficiency on thermosets. The scanning electron microscopy (SEM) results shows that HAP-DOPO in DGEBA/DDS system obviously accelerate formation of the sealing, stronger and phosphorus-rich char layer to improve flame retardant properties of matrix during combustion.     

Effect of anion of polyoxometalate based organic–inorganic hybrid material on intumescent flame retardant polypropylene

In this work, 12‐tungestocobaltic acid based organic–inorganic hybrid material, [Bmim]₆CoW₁₂O₄₀ (CoW) was synthesized and applied as a synergist in polypropylene (PP)/intumescent flame retardant (IFR) composites. The flame retardant properties were investigated by the limiting oxygen index (LOI), UL‐94 vertical burning test, thermal gravimetric analyzer (TGA), cone calorimeter and scanning electron microscopy (SEM) etc. The results showed that the PP composites with 16 wt% IFR and 1 wt% CoW achieves the UL‐94 V‐0 rating and gets a LOI value 28.0. However, only add no less than 25 wt% single IFR, can the PP composites obtain the UL‐94 V‐0 rating, which suggests that CoW has good synergistic effects on flame retardancy of PP/IFR composites. In addition, the SEM and cone calorimeter tests indicated the CoW improves the quality of char layer. The rate of char formation has been enhanced also because of the existence of CoW. It is the combination of a better char quality and a high rate of char formation promoted by CoW that results in the excellent flame retardancy of PP/IFR composites. Copyright © 2016 John Wiley & Sons, Ltd.     

Thermal degradation and flame retardancy of fumaric acid in thermoplastic polyurethane elastomer

In this paper, fumaric acid (FA) which was a new type of environmental and low‐cost flame retardant was applied for thermoplastic polyurethane elastomer (TPU). The flame‐retardant properties of TPU were tested using limiting oxygen index, cone calorimeter test, smoke density test, and thermogravimetric/Fourier transform infrared spectroscopy. It has been proved that FA could improve the difficulty of the ignition of the sample; the limiting oxygen index value of the sample (FA‐4) increased by 29.7% when 2.0 wt% FA was added to TPU. The cone calorimeter test showed that FA can greatly reduce heat release and smoke production during the combustion process of TPU composites. For example, compared with the pure TPU, the peak heat release rate and total smoke release of the sample (FA‐4) with 2.0 wt% FA were decreased by 50.8% and 51.5% respectively. The results of smoke density test showed that the luminous flux of the samples contained 0.5 wt% FA was increased by 79.2% compared with the pure TPU. The TG results revealed that the sample of FA‐4 had higher char residue content compared with the sample of TPU. The results of thermogravimetric/Fourier transform infrared spectroscopy proved that FA could decrease the initial decomposition temperature for TPU composites and increase the release of CO₂ and H₂O. All results of test illustrated that FA had good flame‐retardant effect on TPU.     

Flame retardancy mechanisms of aryl phosphates in combination with boehmite in bisphenol A polycarbonate/acrylonitrile-butadiene-styrene blends

The influence of nano-dispersed 5 wt.% boehmite (AlOOH) and 5 wt.% AlOOH combined with bisphenol A bis(diphenyl phosphate) (BDP) in bisphenol A polycarbonate/acrylonitrile-butadiene-styrene (PC/ABS) + poly(tetrafluoroethylene) (PTFE), and 1 wt.% AlOOH with and without BDP, resorcinol bis(diphenyl phosphate) (RDP), and triphenyl phosphate (TPP), on PC/ABS + PTFE has been investigated. Possible flame retardancy mechanisms are revealed. Thermogravimetry (TG) and evolved gas analysis (TG-FTIR) are used to study pyrolysis, a cone calorimeter applying different external heat fluxes is used to investigate fire behaviour, and LOI and UL 94 are used to investigate flammability. Fire residues were investigated using ATR-FTIR.Adding 5 wt.% AlOOH decreases the peak heat release rate, as also has been reported for polymer nanocomposites with other layered structures. AlOOH releases water, and adding 5 wt.% AlOOH crucially influences thermal decomposition by enhancing the hydrolysis of PC and of BDP. For PC/ABS + PTFE + BDP + 5 wt.% AlOOH, the formation of AlPO₄, for instance, results in antagonistic effects on the charring of PC + BDP, whereas synergy is observed in LOI. When only 1 wt.% AlOOH is added to the PC/ABS + PTFE with and without BDP, RDP and TPP, respectively, no significant influence is observed on thermal decomposition, UL 94, LOI or performance in the cone calorimeter.     

Novel DOPO-based flame retardants in high-performance carbon fibre epoxy composites for aviation

Two novel, halogen-free, phosphorus-based oligomeric flame retardants are investigated in the commercial epoxy resin RTM6 and ∼70 wt.% carbon fibre RTM6 composites (RTM6-CF) with respect to pyrolysis and fire behaviour. The flame retardants are based on 9,10-dihydro-9-oxy-10-phosphaphenanthrene-10-oxide (DOPO) units linked to the star-shaped aliphatic ground body tetra-[(acryloyloxy)ethyl] pentarythrit (DOPP), or heterocyclic tris-[(acryloyloxy)ethyl] isocyanurate (DOPI), respectively. The glass transition temperature is reduced by adding DOPP and DOPI, but the mechanical properties of the composites (e.g. interlaminar shear strength (ILSS) and G_c in mode I and II) remain unchanged. Decomposition models are proposed based on mass loss, evolved gas analysis (TG–FTIR) and condensed product analysis (hot stage cell within FTIR). The fire behaviour is investigated comprehensively (UL 94, limiting oxygen index (LOI) and cone calorimeter). Both flame retardants act in the gas phase through flame inhibition and in the condensed phase through charring. The UL 94 of RTM6 is improved from HB to V-1 and V-0; the LOI from 25% to 34–38%. Peak heat release rate (PHRR) and total heat evolved (THE) are lowered by 31-49% and 40–44%, respectively. Adding CF increases the residue, reduces the THE, but suppresses the charring due to RTM6 and flame retardants. Thus the THE of RTM6-CF is reduced by about 25% when DOPI and DOPP are added. However, UL 94: V-0 and LOI of 45% and 48% are achieved with ∼0.6 wt.% phosphorus.     

磷杂菲类阻燃剂的合成及其与聚磷酸铵复合膨胀体系对环氧树脂的阻燃性能研究

以9,10-二氢-9-氧杂-10-磷杂菲-10-氧化物(DOPO)、五硫化二磷(P2S5)为原料合成9,10-二氢-9-氧杂-10-磷杂菲-10-硫化物(DOPS),并将DOPS与聚磷酸铵(APP)组成复合阻燃剂,用于环氧树脂(EP)的阻燃改性.通过氧指数(LOI)、垂直燃烧(UL-94)、热失重(TGA)、锥形量热(CONE)和扫描电镜(SEM)等方法对改性后的环氧树脂的阻燃性能和阻燃机理进行了测试和分析.实验结果表明,DOPS/APP阻燃体系对EP具有很好的阻燃性能,且复配阻燃剂的阻燃效果比单一的阻燃剂阻燃效果好;其中,当阻燃剂的总添加量达到30%时即W_(DOPS)=10%、W_(APP)=20%时,阻燃EP复合材料的LOI值可达到29.2%,垂直燃烧等级达到UL-94 V-0级,残炭量可达49.3%.     

Flame retardation of glass-fibre-reinforced polyamide 6 by a novel metal salt of alkylphosphinic acid

Aluminum salts of phosphinic acid mixture of diisobutylphosphinic acid and monoisobutylphosphinic acid (HPA-2TBA-Al) and glass fibres were compounded with polyamide 6 to prepare a series of flame retardant GF/PA6 composites via melt blending. The flame retardance and burning behaviors of the composites were investigated by limiting oxygen index (LOI), vertical burning test (UL-94), and Cone calorimeter test. The thermal properties and decomposition kinetics were investigated by thermogravimetric analysis (TGA) under N₂ atmosphere. Addition of HPA-2TBA-Al results in an increased LOI value, a UL-94 V-0 rating together with a decrease in both the values of PHRR and THR in Cone calorimetric analysis. Visual observations and scanning electronic microscopy (SEM) after flame retardant tests confirmed the char-formation which acts as a fire barrier in condense phase. Analysis of cone calorimeter data indicates that gas phase flame retardant mechanism exists in the GFPA6/HPA-2TBA-Al system.     

Preparation and flammability of a novel intumescent flame-retardant poly(ethylene-co-vinyl acetate) system

A phosphorus-containing flame retardant, 4-(5,5-dimethyl-2-oxo-1,3,2-dioxaphosphorinan-2-yloxymethyl)-2,6,7-trioxa-1-phospha-bicyclo[2.2.2]octane-1-oxide (MOPO), was synthesized successfully and characterized. The flame retardancy and thermal behavior of a new intumescent flame-retardant (IFR) system for EVA, which was made of MOPO and ammonium polyphosphate (APP), were investigated by limiting oxygen index (LOI) test, vertical burning test (UL-94), cone calorimeter, and thermogravimetric analysis (TGA). An LOI value of 28.4 and UL-94 V-0 rating can be achieved when the total loading of MOPO and APP was 30 wt.%. The results from cone calorimeter indicate that both the heat release rate (HRR) and the total heat release (THR) of IFR-EVA decreased significantly compared with those of neat EVA. TG curves showed that the amount of residues increased significantly when intumescent additives were added; it also could be found that the LOI values increased with the increase in char residues. Meanwhile, morphology of the residues obtained from burning IFR-EVA in LOI test was studied through the SEM observations and rich compact char layers could explain the excellent flame retardance.     

Study on combustion property and synergistic effect of intumescent flame retardant styrene butadiene rubber with metallic oxides

Effect of metallic oxides on flame retardancy and the thermal stability of styrene butadiene rubber (SBR) composites based on ammonium polyphosphate (APP) and pentaerythritol (PER) was studied by the limiting oxygen index (LOI), UL 94, the cone calorimeter tests, and thermogravimetry analysis (TGA), respectively. Scanning electron microscopy (SEM) and wide‐angle X‐ray diffraction (WAXD) were used to analyze the morphological structure and the component of the residue chars formed from the SBR composites accordingly. The addition of zirconium dioxide (ZrO₂) at a loading of 3.4 phr could improve the UL 94 test rating of the composite to V‐0. The TGA data illustrated that the metallic oxides could enhance the thermal stability of the SBR/Intumescent flame retardant additives (IFRs) composites at high temperature and increase the residue. Cone calorimeter test gave much clear evidence that the incorporation of ZrO₂ into SBR/IFRs composites resulted in the significant deduction of the heat release rate (HRR) values, and the SEM images showed that the char layers of the composites containing the metallic oxides became more compact. From the WAXD pattern, zirconium phosphate (ZrP₂O₇) may be formed by the reaction between ZrO₂ and APP. Due to the addition of ZrO₂ and the formation of ZrP₂O₇, the flame retardancy of the composite was improved. Copyright © 2009 John Wiley & Sons, Ltd.     

A novel phosphazene cyclomatrix network polymer: Design, synthesis and application in flame retardant polylactide

A novel phosphazene cyclomatrix network polymer poly(cyclotriphosphazene-co- pentaerythritol) (PCPP) was synthesized and characterized based on an attempt to look for a high efficient and green intumescent flame retardant. A series of flame retardant polylactide (FR-PLA) composites containing PCPP were prepared by melt blending method. Thermal degradation behavior and combustion properties of FR-PLA composites were evaluated through thermogravimetric analysis, UL-94 experiments, limiting oxygen index and cone calorimeter tests. It is found that the weight of residues for FR-PLA composites improved greatly with the addition of PCPP. Additionally, PCPP show a high flame retardant efficiency for PLA, UL-94 V-0 could be passed only containing 5 wt% PCPP. Fourier transform infrared spectra and scanning electronic microscopy investigations reveal that the residual chars are compact and foaming containing P-O-C structure, which restrains the development of fire and increases the flame retardant properties.     

Preparation, properties and characterizations of halogen-free nitrogen-phosphorous flame-retarded glass fiber reinforced polyamide 6 composite

Halogen free nitrogen-phosphorous flame retardants (PMOP) were prepared through reaction of melamine and polyphosphoric acid in the presence of flame retardant modifier CM with silicotungistic acid as a catalyst in aqueous solution. FT-IR, XRD, DSC and TGA techniques were used to characterize the reaction product PMOP. The obtained flame retardants were then used to prepare flame retardant (FR) polyamide 6 (PA6) composite reinforced with glass fiber (GF) and the factors affecting the flame retardancy of the material were also investigated. The FR GF reinforced PA6 composite and the obtained charred layers were analyzed by utilizing TGA, SEM, FT-IR and XRD. The properties of the charred layer were connected with the flame retardancy of the corresponding material to reveal the flame retarding mechanism of FR GF reinforced PA6 composite. The experimental results show that PMOP flame retardant consists of melamine polyphosphate, melamine phosphate and possible melamine pyrophosphate. The presence of CM was found to improve the flame retardancy of FR GF reinforced PA6 composite. It was experimentally found that PMOP flame retardant, which is comparatively stable in the range of processing temperatures of PA6, is particularly suitable for flame retarding PA6 reinforced with GF. With increasing the flame retardant content, the flame retardancy of the FR reinforced material is not improved so obviously. However, the increase in the GF content greatly improves the flame retardancy of the composite, because GF greatly increases the char yield of material, decreases the maximal thermal decomposition rate, promotes the formation of charred layer with (PNO)_x structure and greatly increases the strength of the charred layer. The prepared FR GF reinforced PA6 composites have good comprehensive properties with flame retardancy 1.6 mm UL 94 V-0 level, tensile strength 76.8 MPa, Young's modulus 11.7 GPa, Izod notched impact strength 4.5 kJ/m², flexural strength 98.0 MPa and flexural modulus 7.2 GPa, showing a better application prospect.     

Effects of a semi‐bio‐based triazine derivative on intumescent flame‐retardant polypropylene

A semi‐bio‐based synergist (N, N′, N″‐1, 3, 5‐triazine‐2, 4, 6‐triyltris‐glycine [TTG]) was prepared by using glycine and cyanuric chloride. The structure of TTG was characterized by ¹H NMR and Fourier transform infrared spectroscopy. The TTG was applied in polypropylene (PP)/intumescent flame‐retardant compounds to improve its flame retardancy. The flame‐retardant properties of PP compounds were evaluated by limiting oxygen index and vertical burning tests (UL‐94). The results showed that 17 wt% intumescent flame‐retardant and 1 wt% TTG makes PP achieve the UL‐94 V‐0 rating without drippings, and the limiting oxygen index value is increased to 29.5 vol%. The thermal degradation behavior and char morphology of PP compounds were investigated by thermogravimetric analysis and scanning electron microscopy. The results indicated that TTG accelerates the formation of char layer, regulates the porous structure of char layer, and enhances its barrier property. Therefore, the temperatures of PP compound after two ignitions during the UL‐94 test are decreased significantly as shown in infrared thermal imaging. In addition, the combustion characteristics of PP compounds were investigated by cone calorimeter. The peak of heat release rate (PHRR) of PP compound is 67% reduced, and the t_PHRR is delayed from 223 to 430 seconds, indicates that the combustion risk of PP compound is reduced.     

Mechanical and fire retardant properties of EVA/clay/ATH nanocomposites - Effect of particle size and surface treatment of ATH filler

Mechanical and flame retardant properties of ethylene vinyl acetate (EVA) copolymer/organoclay/alumina trihydrate (ATH) nanocomposites have been studied. ATH with different particle sizes, ATH1 (2.2-5.2 μm) and ATH2 (1.5-3.5 μm), and three different surface treatments, uncoated, fatty acid coated and silane coated, have been used. A synergistic effect was observed in EVA/organoclay/ATH nanocomposites with the total heat evolved (THE) and the heat release rate (HRR) lower than that of EVA/ATH composite. It was also found that mechanical and flame retardant properties are affected in different ways by the particle size and the surface treatment of ATH fillers. Improvements in tensile and flame retardant properties were observed in nanocomposites when uncoated ATH fillers and fatty acid coated ATH2 filler were used. On the other hand, silane coating on ATH1 and ATH2 improves limiting oxygen index (LOI) and leads to higher t_ignition and the best char stability after cone calorimeter test.     

Synergistic effects between iron–graphene and melamine salt of pentaerythritol phosphate on flame retardant thermoplastic polyurethane

A comparison of melamine salt of pentaerythritol phosphate (MPP), and a synergistic agents, iron–graphene (IG) was performed in thermoplastic polyurethane (TPU) by masterbatch‐melt blending on thermal and flame retardant properties. The flame retardant properties of TPU composites were characterized by limiting oxygen index (LOI), UL 94 and cone calorimeter test (CCT). The CCT results revealed that IG can significantly enhance flame retardant properties of MPP in TPU. The peak heat release rate of neat TPU and flame retardant TPU/MPP composites decreased from 2192.6 and 226.7 to 187.2 kW/m² compared with that of TPU containing 0.25 wt% IG. The thermal stability and thermal decomposition of TPU composites were characterized by thermogravimetric analysis (TGA) and thermogravimetric/Fourier infrared spectrum analysis (TG‐IR). The results indicated IG and MPP can improve the thermal stability of TPU. The formation of thermal conductive network by IG can promote the decomposition of MPP into nonflammable melt, which can play the role of heat barrier and restrict the diffusion of fuels into combustion zone and access of oxygen to the unburned fuels. Copyright © 2016 John Wiley & Sons, Ltd.     

Experimental study on liquid fire behavior at different effective ceiling heights in a full-size simulated cargo compartment

A phosphorus-containing maleimide flame retardant (BDMP) was synthesized via the addition reaction between 9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide and N,N′-bismaleimide-4,4′-diphenylmethane. The structure of BDMP was characterized by Fourier-transform infrared spectroscopy (FTIR), ¹H and ³¹P nuclear magnetic resonance and elemental analysis. The thermal, flame-retardant and mechanical properties of the flame-retardant cyanate ester system were investigated by thermogravimetric analysis (TG), limiting oxygen index (LOI), vertical burning (UL-94), cone calorimeter test and dynamic mechanical analysis. The TG results indicated that the initial decomposition of modified CE resin shifted from 416 to 363 °C, and on the contrary, the char yield increased from 38.8 to 44.5%. The results of combustion tests indicated that the CE with highest phosphorus content acquired LOI value of 37% and achieved a UL-94 V-0 rating. The peak heat release rate, average heat release rate and average of effective heat combustion (av-EHC) of that group decreased by 39.5, 31.2 and 41.8%, respectively. In addition, the increase in phosphorus content led to a decrease in av-EHC and average CO₂ yield, and an increase in average CO yield, indicating that BDMP led to an incomplete combustion of the modified CE system. The flame-retardant mechanism was investigated by TG–FTIR, scanning electron microscope and cone calorimeter. Last but not least, the dielectric constant of modified CE system showed a slight fluctuation from 2.96 to 3.02 at 1 GHz, which was lower than that of neat CE.     

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.