Calcium and aluminium-based fillers as flame-retardant additives in silicone matrices. I. Blend preparation and thermal properties

This series investigates silicone composites with enhanced thermal behaviour for cable applications. Calcium and aluminium-based fillers introduced into silicone formulations were classified according to three categories: non-hydrated fillers such as CaCO₃ (precipitated calcium carbonate and natural calcite) and wollastonite, water-releasing fillers such as calcium hydroxide, ATH, boehmite, and hydroxyl-functionalized fillers including alumina and mica. The fillers were first characterized in detail, and the thermal stability of their blends with silicone was recorded by thermogravimetric analyses. A discussion on various aspects of the filler morphology (size, microstructure, release profile with temperature) on the silicone stability is finally given.     

Influence of additives on recycled polymer blends

Polymer systems based on polymer waste offer promising way to increase recycling in the society. Since fillers play a major role in determining the properties and behavior of polymer composites, recycled polymers can also be combined with fillers to enhance the stiffness and thermal stability. In this study, blends of recycled polyethylene and recycled polypropylene with mica and glass fiber were prepared by melt blending technique. The effect of the particle loading, filler type, and filler–matrix interaction on thermal degradation and thermal transition of processed systems were investigated. Thermogravimetric analysis, differential thermogravimetric analysis, and differential scanning calorimetry were used in this investigation. Comparative analysis shows that both fillers produced different effects on thermal properties of the processed systems. These results were confirmed by calculating the activation energy for thermal degradation and thermal transition using Kissinger and Flynn–Wall expressions.     

An Electroconductive Filler for Shielding Plastics

A well characterised grade of mica was used to prepare nickel-coated mica fillers by an electroless coating technique. These fillers were incorporated into polypropylene (PP) and acrylonitrile-butadiene-styrene (ABS) using a Haake Internal mixer and a two-roll mill to produce conducting composites suitable for EMI shielding applications. Compounded polymers were fabricated into sheets of different thickness by compression moulding. The dependence of conductivity on sample thickness was studied and samples were tested for electrical resistivity, shielding efficiency, and thermal and mechanical properties. Reduced sample thickness during compression moulding decreased the electrical resistance of the polymer composites due to orientation and the formation of a good conducting network. Volume resistivity of PP composites was lower than for ABS composites with 50% Ni coating and equivalent filler weight fracions, showing that better conductivity could be achieved in a semi crystalline polymer than in an amorphous polymer. 0.6 weight fraction of 50 wt.% nickel coated mica in ABS showed a shielding efficiency of 16dB compared with 27.8dB in PP.     

Thermal properties of single walled carbon nanotube‐silicone nanocomposites

The effect of single walled carbon nanotube (SWCNT) fillers on the low temperature thermal properties and curing behavior of SWCNT‐silicone nanocomposite are reported for the first time. The SWCNT‐silicone composites were prepared by different mixing procedures and characterized by differential scanning calorimetry (DSC). Solution mix, with the aid of sonication and soaking achieved better dispersion of SWCNTs in the silicone. The adding of SWCNTs in polymer seriously hindered the curing of silicone elastomer. The hindrance increased with increasing concentration of SWCNT and the quality of dispersion. The glass transition temperatures (T_g) of the nanocomposites were found to be independent of the SWCNT addition, although, the steps in the heat capacity (Δc_p) of the glass transition were smaller with increasing SWCNTs concentration. The melt crystallization behavior was strongly dependent on the concentration and dispersion of SWCNT in the polymer. The cooling scan showed that the higher concentration and the better dispersion of SWCNTs in the silicone resulted in higher percentage of melt crystallization of this nanocomposite. The correlation of the change of thermal properties to the dispersion of CNT in polymer may be used to determine the quality of SWCNT dispersion in silicone polymer. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 1845–1852, 2008     

Thermal stability of styrene–(ethylene butylene)–styrene-based elastomer composites modified by liquid crystalline polymer, clay, and carbon nanotube

The thermal decomposition behaviors of styrene?C(ethylene butylene)?Cstyrene (SEBS) thermoplastic elastomer filled with liquid crystalline polymer (LCP), organomontmorillonite (OMMT), and carbon nanotube (CNT) as a heat stabilizing filler, were comparatively investigated using nonisothermal- and isothermal-thermogravimetric analyses in air. The isoconversional method was employed to evaluate the kinetic parameters (E _a, lnA, and n) under dynamic heating. For neat samples, OMMT and CNT exhibited their respective lowest and highest thermal stabilities as revealed from the lowest and the highest T _onset values, respectively. The decomposition rates of the composites containing OMMT at the temperature >250?°C were higher than those containing CNT and LCP, respectively, whereas the elastomer matrix degraded with the highest rate. The obtained TG profiles and calculated kinetic parameters indicated that the incorporation of LCP, OMMT, and CNT into elastomer matrix improved the thermal stability. Especially, the CNT- and OMMT-containing composites significantly improved the thermal stability compared with the neat matrix polymer. Simultaneously recorded DSC thermograms revealed that the degradation processes for the neat polymers and their composites were exothermic in air. From the simultaneously recorded DSC data, the enthalpy of thermal decomposition for each composite system was found to be lower than that of the neat matrix and mostly decreasing with increasing filler loading. The isothermal decomposition stabilities of the neat SEBS and its composites containing the different fillers were in agreement with those of the nonisothermal investigation.     

Moisture–absorption,dielectric relaxation,and thermal conductivity studies of polymer composites

In the search for new packaging materials for the electrical/electronics industry, three types of polymer composites have been studied. Silicone/boron nitride powders, polyurethane/alumina powders, and polyurethane/carbon fibers have all been synthesized to study the moisture–absorption kinetics, thermal conductivities, and the dielectric loss spectra under various levels of humidity. The water uptake data indicate that water molecules are absorbed not only by the polymer matrix, but also by the interfaces introduced by the fillers. For all materials, the dielectric relaxation spectroscopy shows the presence of a peak in the 175–200 K range, which is largely due to absorbed water. The silicone/boron nitride samples absorbed the least amount of moisture. Incorporating this result with the thermal conductivity data of the three types of polymer composites, it is concluded that silicone polymers embedded with boron nitride can best serve as the coating for the electronic devices that require heat dissipation and moisture resistance, in addition to electrical insulation. © 1998 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 36: 2259–2265, 1998     

Synergetic effect of thermal conductivity and flame retardancy of cyanate ester composites containing DOPO and BN with great dielectric properties

DOPO and boron nitride (BN) fillers with different particle sizes and several loadings were employed to improve the properties of cyanate ester (CE) resin. The effects of BN content and particle size on the thermal conductivity of the BN‐DOPO/CE ternary composites were discussed. The influence of enhancing the thermal conductivity of the ternary composites on their flame retardancy was studied. The consequences showed that increasing the thermal conductivity of BN‐DOPO/CE composites had an active impact on their flame retardancy. Approving flame retardancy of the ternary composites was certified by the high limiting oxygen index (LOI), UL‐94 rating of V‐0, and low heat release rate (HRR) and total heat release (THR). For instance, in contrast with pure CE matrix, peak of HRR (pk‐HRR), average of HRR (av‐HRR), THR, and average of effective heat of combustion (av‐EHC) of CEP/BN_{0.5 μm}/10 composite were decreased by 51.7%, 33.8%, 18.7%, and 18.9%, respectively. Thermal gravimetry analysis (TGA) showed that the addition of BN fillers improves the thermal stability of the composites. Moreover, the ternary composites possess good dielectric properties. Their dielectric constants (ε) are less than 3, and dielectric loss tangent (tgδ) values are lower than neat CE resin.     

Nanosize and microsize clay effects on the kinetics of the thermal degradation of polylactides

Polylactide (PLA)-montmorillonite (MMT) micro- and nanocomposites based on semicrystalline and amorphous polymers and unmodified or organomodified clays at 5 wt% content were produced by melt mixing. Based on the three different test methods that were used to follow thermal degradation, different conclusions were obtained. During melt processing, thermomechanical degradation was more pronounced in the presence of all fillers, which apparently acted catalytically, but to different degrees. During isothermal degradation in air from 180 °C to 200 °C, degradation rate constants were calculated from novel equations incorporating changes in intrinsic viscosity (IV). Results show that the thermal degradation rate constants of the amorphous PLA and its composites are lower than those of the semicrystalline PLA and its composites. Due to better filler dispersion in the polymer matrix, the thermal degradation rate constants of the nanocomposites are significantly lower than those of the unfilled polymers and their microcomposites under air. As per dynamic TGA data and thermal kinetic analysis from weight losses and activation energy calculations, organomodified nanofillers have a complex effect on the polymer thermal stability; the unmodified fillers, however, reduce polymer thermal stability. These TGA data and kinetic analysis results also support the findings that the thermal stability of the amorphous PLA and its composites is higher than that of the semicrystalline polymer and its composites and the thermal stability of the nanocomposites is higher than that of the microcomposites. In general, mathematical modeling based on random thermal scission equations was satisfactory for fitting the TGA experimental data.     

Structure–property relationship of octa‐substituted POSS in thermal and mechanical reinforcements of conventional polymers

In this article, we describe the structure–property relationships between the polyoctahedral oligomeric silsesquioxane (POSS) fillers and the thermomechanical properties of the polymer composites using polystyrene, poly(methyl methacrylate), and ethylene‐(vinyl acetate) copolymer. We used eight kinds of octa‐substituted aliphatic and aromatic POSS as a filler, and homogeneous polymer composites were prepared with various concentrations of these POSS fillers. From a series of measurements of thermal and mechanical properties of the polymer composites, it was summarized that the longer alkyl chains and unsaturated bonds at the side chains in POSS are favorable to improve the thermal stability and the elasticity of polymer matrices. It was found that phenyl‐POSS can show superior ability to improve the thermomechanical properties of conventional polymers used in this study. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 5690–5697, 2009     

Thermal decomposition kinetics,flammability, and mechanical property study of wood polymer nanocomposite

Melamine formaldehyde-furfuryl alcohol copolymer was impregnated into softwood in combination with 1,3-dimethylol-4,5-dihydroxy ethyleneurea, a crosslinking agent, nanoclay, and a renewable polymer, collected as gum from a local plant (Moringa oleifera) under vacuum condition and polymerized by catalyst heat treatment. Fourier-transform infrared spectroscopy, X-ray diffractometry, and scanning electron microscopy were used to characterize the nanocomposites. Transmission electron microscopy showed uniform distribution of nanoclay in the composites. The mechanical properties were improved after the addition of plant polymer. The plant polymer had a marked influence on the flammability and thermal stability of the prepared composites. The apparent activation energy was determined by Ozawa-Flynn-Wall’s and Vyazovkin methods. The activation energy of the composites decreased up to a certain decomposed fraction thereafter it remained constant. Higher the plant polymer content higher was the activation energy of the prepared composites which indicated a better interfacial adhesion and thermal stability.     

Thermogravimetry as a Method for Investigating the Thermal Stability of Polymer Composites

Thermogravimetry was used to investigate the effects of different inorganic functional fillers on the heat resistance of polymer matrices. The kinetic parameters of thermal oxidative degradation were shown to depend on the polymer, the chemical composition of the filler surface, the filler concentration, and the processing method, which determines the distribution of filler particles in the polymer matrix. Magnetic fillers (carbonyl iron, and hexaferrites of different structural types) were shown to be chemically active fillers, increasing the heat resistance of siliconorganic polymers. Their stabilizing effect is due to blocking of the end silanol groups and macroradicals by the surface of the filler and non-chain inhibition of thermal oxidative degradation. In the case of fiber-forming polymers (UHMWPE, PVOH and PAN), most magnetic fillers are chemically inert, but at concentrations of 30–50 vol% they increase the heat resistance of the composite. Addition of carbon black increased the heat resistance of the thermoplastic matrix. The dependence of the thermal degradation onset temperature on the kaolin concentration in the polyolefin matrix exhibited a maximum. Analysis of the experimental results demonstrated the operating temperature ranges for different composites, and their maximum operating temperature. This revised version was published online in July 2006 with corrections to the Cover Date.     

Thermal and mechanical properties of particulate fillers filled epoxy composites for electronic packaging application

Epoxy composites containing particulate fillers‐fused silica, glass powder, and mineral silica were investigated to be used as substrate materials in electronic packaging application. The content of fillers were varied between 0 and 40 vol%. The effects of the fillers on the thermal properties—thermal stability, thermal expansion and dynamic mechanical properties of the epoxy composites were studied, and it was found that fused silica, glass powder, and mineral silica increase the thermal stability and dynamic thermal mechanical properties and reduce the coefficient of thermal expansion (CTE). The lowest CTE value was observed at a fused silica content of 40 vol% for the epoxy composites, which was traced to the effect of its nature of low intrinsic CTE value of the fillers. The mechanical properties of the epoxy composites were determined in both flexural and single‐edge notch (SEN‐T) fracture toughness properties. Highest flexural strength, stiffness, and toughness values were observed at fillers content of 40 vol% for all the filled epoxy composites. Scanning electron microscopy (SEM) micrograph showed poor filler–matrix interaction in glass powder filled epoxy composites at 40 vol%. Copyright © 2007 John Wiley & Sons, Ltd.     

Thermal and water absorption properties of cyanate ester resins modified by fluoride‐containing and silicone‐containing components

In order to enhance the moisture resistance of cyanate ester resins, modifiers containing silicon or fluorine moieties were introduced. The curing behaviors of the obtained resins, as well as thermal, water absorption, and dielectric properties of all cured polymers, were investigated in detail. Results show that properties of fillers in polymer have great influence on the thermal property and of polymer. In all cases, modifier exhibited percolation threshold at 5 wt%. Compared with pristine cyanate ester resins (CE), when the methyl phenyl silicone resin B filler was added, the cured polymer exhibited water absorption as low as 0.39% and excellent thermal oxygen stability at 300°C. The introduction of silicon H improved thermal oxidative stability at 400°C without significant compromise in processability or mechanical properties.     

Calcium and aluminum-based fillers as flame-retardant additives in silicone matrices. III. Investigations on fire reaction

The flame retardancy of silicone composites containing calcium- and aluminum-based fillers has been investigated using several methods including cone calorimeter, Pyrolysis Combustion Flow Calorimeter (PCFC), thermogravimetric analysis and pyrolysis-gas chromatography-mass spectrometry analysis (Py-GC/MS). The fire reaction of precipitated calcium carbonate, calcite, calcium hydroxide, aluminum trihydrate, boehmite and alumina-based composites was correlated mainly with their thermal stability, while for mica and wollastonite-based composites, a barrier effect was also evidenced. The endothermic effect was not established as an efficient flame retardancy mechanism for the silicone composites containing hydrated fillers. Mica composite exhibited the best flame retardancy, in terms of depressed HRR, among all investigated formulations. Finally, a unique behavior was observed during the cone calorimeter test of calcium hydroxide-based composite, which co-crystallization with silica occurs exclusively at high heat flux.     

Influences of coupling agent on thermal properties, flammability and mechanical properties of polypropylene/thermoplastic polyurethanes composites filled with expanded graphite

In this study, polypropylene (PP)/thermoplastic polyurethanes (TPU) filled with inorganic intumescent flame retardant expanded graphite (EG) was prepared by melt blending in a twin-screw extruder. The thermal stability, fire retardancy, mechanical properties, and fracture morphology of PP/TPU composites with treated and untreated EG were investigated by thermogravimetric analysis, cone calorimeter, and scanning electron microscope. The results showed that both untreated and treated EG can greatly enhance the thermal stability and fire resistance of polymer matrix materials. Compared with untreated EG, treated EG can further improve the flame retardancy of the composites. For example, treated EG can further reduce the heat release rate, total heat release, and CO emissions of the composites in the combustion. Surface treatment of EG could significantly improve elongation at break and impact strength of PP/TPU/EG composites due to its enhanced interfacial adhesion and the good dispersion of EG particles in the polymer matrix.     

Flame retardant effects of organic inorganic hybrid intumescent flame retardant based on expandable graphite in silicone rubber composites

In this work, an organic inorganic hybrid intumescent flame retardant (functionalized expandable graphite, FEG) was synthesized and characterized by Fourier transform infrared spectrometry (FTIR). The flame retardant effects of FEG in silicone rubber (SR) composites were investigated by cone calorimeter test (CCT), and the thermal stability of SR composites was studied using TGA. The CCT results showed that FEG can effectively reduce the flammable properties including peak heat release rate (PHRR), total heat release (THR), smoke production rate (SPR), total smoke release (TSR), and smoke factor (SF). An improvement of thermal stability of SR/FEG was also observed. Compared with EG, FEG can further reduce THR, SPR, and TSR of SR/FEG composites in combustion process. Moreover, there is a more obvious intumescent char layer formed from the sample with FEG than the sample with EG at the same loading in SR composites. Copyright © 2014 John Wiley & Sons, Ltd.     

碳酸钙与碳化硅对室温硫化硅橡胶的补强作用

在有关硅橡胶补强的研究中,人们已经对ＳｉＯ２ 等补强性填料对硅橡胶的补强作用进行了深入的研究,但对非补强填料对室温硫化硅橡胶的补强作用则相对涉及较少．作者研究了ＣａＣＯ３ 和ＳｉＣ 两类非补强性填料以及填料的粒径与分布对室温硫化硅橡胶拉伸强度、断裂伸长率和耐温性能等的影响,发现合适粒径的非补强性填料对室温硫化硅橡胶有较好的补强效果,且在填料粒径及分布匹配时有最好的补强效果,选用ＳｉＣ时还可以有效提高室温硫化硅橡胶的热稳定性．     

Thermal characterization of Al2O3 and ZnO reinforced silicone rubber as thermal pads for heat dissipation purposes

Silicone rubber filled with thermally conductive, but electrically insulating Al₂O₃ or ZnO fillers were investigated to be used as elastomeric thermal pads, a class of thermal interface materials. The effect of Al₂O₃ or ZnO fillers on the thermal conductivity and coefficient of thermal expansion (CTE) of the silicone rubber were investigated, and it was found that with increasing Al₂O₃ or ZnO fillers, the thermal conductivity of the thermal pads increases, while the coefficient of thermal expansion (CTE) decreases. The thermal conductivity results obtained were also analyzed using the Agari model to explain the effect of Al₂O₃ or ZnO fillers on the formation of thermal conductive networks. Thermal gravimetry analysis (TGA) showed that the addition of either Al₂O₃ or ZnO fillers increases the thermal stability of the silicone rubber, while the scanning electron microscope (SEM) showed that at 10 vol.% filler loading percolation threshold has yet to be reached.     

Methods for Characterizing the 3-D Morphology of Polymer Composites

3-dimensional visualization of polymer morphology is of increasing interest in the polymer community because it provides a deeper insight into the arrangement of the phases in heterophasic polymeric materials, for example in composites. Depending on the size of the fillers, an adequate method offering a good compromise between suitable resolution and observable volume must be selected. Different polypropylene composites filled with long glass fibres, mica and talcum particles were investigated. Four methods were applied to account for the different filler sizes. For composites containing fillers larger than several micrometers, i.e. glass fibres and mica particles, X-ray tomography offers a very good combination of visibility and volume. Serial sectioning by polishing in combination with light optical microscopy can be an alternative if no X-ray equipment is available. This combined method has the disadvantage, however, that the imaged volume is smaller and involves more effort, which makes it unsuitable for routine observations. The much smaller talcum particles with thicknesses down to 200 nm were investigated by coupling focused ion beam (FIB) milling and scanning electron microscopy (SEM) and by insitu ultramicrotomy in the SEM. Both methods led to good and comparable results.     

Green synthesis of polymer nanofibers and their composites as flame‐retardant materials for polymer nanocomposites

Polyaniline nanofibers and their composites with carbon nanotubes were developed as an effective flame‐retardant material using a facile green method. Polyaniline nanofibers were used as a smart flame‐retardant for acrylonitrile–butadiene–styrene polymer. The polyaniline nanofibers were dispersed in polymer matrix forming well‐dispersed polymer nanocomposites. Effect of polyaniline nanofiber mass ratio on the polymer nanocomposite properties was studied. Polyaniline nanofiber composites with carbon nanotubes were also dispersed in polymer matrix. The thermal stability and flammability properties of the polymer nanocomposites were investigated. The rate of burning of polymer nanocomposites achieved 82.5% reduction (7.32 mm/min) compared with virgin polymer (42.5 mm/min). The reduction in peak heat release rate and total heat release of the polymer nanocomposites containing nanofibers achieved 74 and 34%, respectively. Interestingly, the average mass loss rate was significantly reduced by 58% and the emission of carbon monoxide and carbon dioxide gases were suppressed by 20 and 47%, respectively. The effect of polyaniline nanofibers composites on the flammability of polymer nanocomposites was also studied. Polyaniline nanofibers and their composites were characterized using Fourier transform infrared spectroscopy and transmission and scanning electron microscopy. The dispersion of polyaniline nanofibers in polymer nanocomposites was characterized using transmission electron microscopy. The different polymer nanocomposites were characterized using thermogravimetric analysis, UL94 flame chamber, and cone calorimeter tests. Copyright © 2016 John Wiley & Sons, Ltd.