Halogen-free flame retardant PUF: Effect of melamine compounds on mechanical, thermal and flame retardant properties

Water blown rigid polyurethane foam (PUF) was prepared with melamine polyphosphate (MPP) and melamine cyanurate (MC) as fire retardant (FR) additives. The effect of these additives on the properties of rigid PUF such as physico-mechanical, morphological, thermo-oxidative stability, flame retardancy and smoke density properties were studied. The mechanical and thermo-oxidative stability of PUF filled with MC was found to be better than those of MPP filled PUF. The insulation property of both MPP and MC filled PUF was improved with respect to the neat PUF. The FR properties of these filled PUF were evaluated by cone calorimeter, limiting oxygen index (LOI), smoke density, rate of burning and char residue estimation. The FR property of MPP filled PUF was better than that of the MC filled PUF.     

The study of mechanical behavior and flame retardancy of castor oil phosphate-based rigid polyurethane foam composites containing expanded graphite and triethyl phosphate

The goal of this work was the synthesis of novel flame-retarded polyurethane rigid foam with a high percentage of castor oil phosphate flame-retarded polyol (COFPL) derived from renewable castor oil. Rigid flame-retarded polyurethane foams (PUFs) filled with expandable graphite (EG) and diethyl phosphate (TEP) were fabricated by cast molding. Castor oil phosphate flame-retarded polyol was derived by glycerolysis castor oil (GCO), H₂O₂, diethyl phosphate and catalyst via a three-step synthesis. Mechanical property, morphological characterization, limiting oxygen index (LOI) and thermostability analysis of PUFs were assessed by universal tester, scanning electron microscopy (SEM), oxygen index testing apparatus, cone calorimeter and thermogravimetric analysis (TGA). It has been shown that although the content of P element is only about 3%, the fire retardant incorporated in the castor oil molecule chain increased thermal stability and LOI value of polyurethane foam can reach to 24.3% without any other flame retardant. An increase in flame retardant was accompanied by an increase in EG, TEP and the cooperation of the two. Polyurethane foams synthesized from castor oil phosphate flame-retarded polyol showed higher flame retardancy than that synthesized from GCO. The EG, in addition to the castor oil phosphate, provided excellent flame retardancy. This castor oil phosphate flame-retarded polyol with diethyl phosphate as plasticizer avoided foam destroy by EG, thus improving the mechanical properties. The flame retardancy determined with two different flame-retarded systems COFPL/EG and EG/COFPL/TEP flame-retarded systems revealed increased flame retardancy in polyurethane foams, indicating EG/COFPL or EG/COFPL/TEP systems have a synergistic effect as a common flame retardant in castor oil-based PUFs. This EG/COFPL PUF exhibited a large reduction of peak of heat release rate (PHRR) compared to EG/GCO PUF. The SEM results showed that the incorporation of COFPL and EG allowed the formation of a cohesive and dense char layer, which inhibited the transfer of heat and combustible gas and thus increased the thermal stability of PUF. The enhancement in flame retardancy will expand the application range of COFPL-based polyurethane foam materials.     

Thermal degradation and flame retardancy of rigid polyurethane foams containing a novel intumescent flame retardant

A novel cheap macromolecular intumescent flame retardants (MIFR) was synthesized, and its structure was a macromolecule containing phosphorus characterized by IR. Rigid polyurethane foam (PUF) filled with MIFR as fire retardant additive was prepared. The effects of MIFR on properties such as density, compressive strength, flame-retardant behavior, thermal stability, and morphology of char were studied. The compressive strength of the MIFR-filled PUF increased initially and then decreased with further increase of MIFR content while its density straightly increased. Its flammability and burning behavior were characterized by UL 94 and limiting oxygen index (LOI). Twenty five percent of MIFR was doped into PUF to get 24.5 of LOI and UL 94 V-0. Activation energy for the decomposition of samples was obtained using Kissinger equation. The resultant data show that for PUF containing MIFR, compared with PUF, the mass loss, thermal stability, and the decomposition activation energy decreased, the char yield increased, which shows that MIFR can catalyze decomposition and carbonization of PUF to form an effective charring layer to protect the underlying substrate.     

软质聚氨酯泡沫塑料用无卤阻燃剂的研究

本文以羟基苯氧膦丙烯酸(CEPP)和三聚氰胺(MA)为原料合成了一种含磷、氮无卤阻燃剂(CMA),采用FT-IR表征了阻燃剂的化学结构,并将该阻燃剂用于软质聚氨酯泡沫(FPUF)的阻燃。用扫描电镜(SEM)研究了阻燃剂的加入对FPUF的形态的影响,通过LO I和垂直燃烧(Cal.117A)测试研究了该阻燃剂对FPUF的阻燃效果。结果表明,CMA可以有效提高FPUF的阻燃性:当CMA的添加量为10%时,FPUF即可通过Cal.117A测试,其LO I值也从17.3提高到23.0;随阻燃剂添加量的增加,FPUF的阻燃性能也逐渐提高。TG测试结果表明CMA的加入对FPUF的热稳定性没有多大影响。     

Thermal stability and flame retardancy of LDPE/EVA blends filled with synthetic hydromagnesite/aluminium hydroxide/montmorillonite and magnesium hydroxide/aluminium hydroxide/montmorillonite mixtures

The combination of organophillised montmorillonite (MMT), synthetic hydromagnesite and aluminium hydroxide (ATH) as flame retardant system for polyethylene-based materials was studied and compared with a similar system with magnesium hydroxide, ATH and MMT. The thermal stability and the flame retardant properties were evaluated by thermogravimetric analysis (TGA), differential thermal analysis (DTA), limiting oxygen index (LOI) and cone calorimeter tests. The results indicated that the addition of montmorillonite makes it possible to reduce the total filler content to achieve the flame retardant requirements. The thermal stability of filled LDPE/EVA blends increases to a higher extent for the samples containing MMT. In the cone calorimeter tests we observed a reduction of the peak heat release rate for the sample containing montmorillonite in comparison with a sample with higher filler loading without this nanoclay. An increase of the stability of the char formed could be responsible for this favourable behaviour when montmorillonite is added.In addition, mechanical properties significantly improved for the composites containing montmorillonite both for the filler loading reduction and the reinforcement effect of the nanoclay.     

Study on fire performance and pyrolysis of polyurethane foam material containing DMMP/TCPP

In this paper, an efficient flame retardant polyurethane foam (PUF) material consisting of phosphorus-halogen flame retardants has been prepared by adding dimethyl methylphosphonate (DMMP) and tris(1-chloro-2-propyl) phosphate (TCPP). The limiting oxygen index measurement and thermal analysis have been used for accessing the flame retardancy and thermal properties of the PUF sample. Thermal decomposition process of the sample and its evolved gaseous products at different temperatures during pyrolyzing have been investigated and identified via thermogravimetric analysis by coupling with Fourier transform infrared spectrometry. Influence of DMMP and TCPP on the evolved gaseous products during pyrolysis has been discussed here.     

The Effect of Glass Fibre and a Phosphorus-Containing Flame Retardant on the Flammability of Recycled PET

The availability of scrap poly(ethylene terephthalate) (PET) from post-consumer bottles is increasing as the post-consumer collecting systems are becoming more usual in daily life. PET is well known as a high-performance engineering thermoplastic because of its good thermal stability, chemical resistance, and excellent mechanical properties. Many efforts have been carried out to use this material in housings of electronic applications. However, the flammability of PET is a shortcoming in some of these applications. In this study, our attempt is to incorporate a non-halogenated flame retardant, in form of a phosphorus-containing compound, together with a commercial glass fibre grade to achieve UL94 test V-0 rating for PET. An investigation of thermal stability and flammability (HDT, UL94 V-test) and mechanical (tensile, flexural and impact tests) properties of glass fibre filled PET samples is reported as a function of fraction of flame retardant. This work shows the influence of the filler content and the interfacial filler/matrix adhesion on the flame retardant and the mechanical properties.     

Synergistic effects of ammonium polyphosphate and red phosphorus with expandable graphite on flammability and thermal properties of HDPE/EVA blends

In this work, the flame‐retardant high‐density polyethylene/ethylene vinyl‐acetate copolymer (HDPE/EVA) composites have been prepared by using expandable graphite (EG) as a flame retardant combined with ammonium polyphosphate (APP) and red phosphorus masterbatch (RPM) as synergists. The synergistic effects of these additives on the flammability behaviors of the filled composites have been investigated by limiting oxygen index, UL‐94 test, cone calorimeter test, thermogravimetric analysis (TGA), Fourier‐transform infrared (FTIR), and scanning electron microscopy. The results show that APP and RPM are good synergists for improving the flame retardancy of EG‐filled HDPE/EVA composites. The data from TGA and FTIR spectra also indicate the synergistic effects of APP and RPM with EG considerably enhance the thermal degradation temperatures but decrease the charred residues of the HDPE/EVA/EG composites because the flame‐retardant mechanism has changed. The morphological observations present positive evidences that the synergistic effects take place in APP and RPM with EG in flame‐retardant EG‐filled HDPE/EVA/EG composites. The formation of stable and compact charred residues promoted by APP and RPM with EG acts as effective heat barriers and thermal insulations, which improves the flame‐retardant performances and prevents the underlying polymer materials from burning. Copyright © 2015 John Wiley & Sons, Ltd.     

Influence of oxidation state of phosphorus on the thermal and flammability of polyurea and epoxy resin

The focus of this study is an investigation of the effect of oxidation state of phosphorus in phosphorus-based flame retardants on the thermal and flame retardant properties of polyurea and epoxy resin. Three different oxidation states of phosphorus (phosphite, phosphate and phosphine oxide) additives, with different thermal stabilities at a constant phosphorus content (1.5 wt.%) have been utilized. Thermal and flame retardant properties were studied by TGA and cone calorimetry, respectively. The thermal stability of both polymers decreases upon the incorporation of phosphorus flame retardants irrespective of oxidation state and a greater amount of residue was observed in the case of phosphite. Phosphate was found to be better flame retardant in polyurea, whereas phosphite is suitable for epoxy resin. Phosphite will react with epoxy resin by trans-esterification, which is demonstrated by FTIR and ³¹P NMR. Further, TG–FTIR and XPS studies also provide information on flame retardancy of both polymers with phosphorus flame retardants.     

Polypropylene composites filled by magnesium hydroxide coprecipitated with foreign ions

Rod‐like magnesium hydroxide (MH) particles were prepared via coprecipitation of the magnesium salt with foreign ions, such as copper(II), zinc(II), iron(III), and nickel(II). Flame retardant polypropylene (PP) composites were fabricated using these particles. The microstructure, flame retardation, mechanical properties, thermal behavior, and oxidation‐induced temperature were characterized. It was found that foreign ion compounds increased the flame retardancy. MH containing a zinc compound presented a similar performance as that of neat MH. The presence of a copper compound decreased the thermal behavior and mechanical properties of the flame retardant composite, while iron and nickel compounds brought some improvements. In addition, the thermal degradation mechanisms of the flame retardant composites were investigated by Fourier transform infrared (FTIR) spectroscopy at different temperatures. Copyright © 2008 John Wiley & Sons, Ltd.     

Thermal and flame retardant properties of novel intumescent flame retardant low-density polyethylene (LDPE) composites

A char-forming agent (CFA) and silica-gel-microencapsulated ammonium polyphosphate (MCAPP) were selected to form novel intumescent flame retardant system (IFRs), and then the influence of this novel IFRs on the thermal and flame retardant properties of low-density polyethylene (LDPE) were studied. The results of cone calorimetry show that the flame retardant properties of LDPE with 30?wt% novel IFR (CFA/MCAPP?=?1:3) improve remarkably. The heat release rate peak, total heat release (THR) decreases, respectively, from 1479.6 to 273.5?kW?m^?2 and from 108.0 to 80.5?MJ?m^?2. The LDPE composite with CFA/MCAPP?=?1:3 has the excellent water resistance, and it can still obtain a UL-94?V-0 rating after treated with water at 70?°C for 168?h.     

Study of the fire resistant behavior of unfilled and carbon nanofibers reinforced polybenzimidazole coating for structural applications

With increasing interest in epoxy‐based carbon fiber composites for structural applications, it is important to improve the fire resistant properties of these materials. The fire resistant performance of these materials can be improved either by using high performance epoxy resin for manufacturing carbon fiber composite or by protecting the previously used epoxy‐based composite with some fire resistant coating. In this context, work is carried out to evaluate the fire resistance performance of recently emerged high performance polybenzimidazole (PBI) when used as a coating material. Furthermore, the effect of carbon nanofibers (CNFs) on fire resistant properties of inherently flame retardant PBI coating was studied. Thermogravimetric analysis of carbon/epoxy composite, unfilled PBI and nano‐filled PBI shows that the carbon/epoxy composite maintained its thermal stability up to a temperature of 400°C and afterwards showed a large decrease in mass, while both unfilled PBI and nano‐filled PBI have shown thermal stability up to a temperature of 575°C corresponding to only 11% weight loss. Cone calorimeter test results show that unfilled PBI coating did not improve the fire retardant performance of carbon/epoxy composite. Conversely, nano‐filled PBI coating has shown a significant improvement in fire retardant performance of the carbon/epoxy composite in terms of increased ignition time, reduced average and peak heat release rate and reduced smoke and carbon monoxide emission. These results indicate that addition of carbon nanofibers to inherently flame retardant coating can significantly be helpful for improving the fire resistance performance of composite materials even with low coating thickness. Copyright © 2013 John Wiley & Sons, Ltd.     

Effect of ethyl‐bridged diphenylphosphine oxide on flame retardancy and thermal properties of epoxy resin

Three commercialized flame retardants, 1,2‐bis(diphenylphosphinoyl)ethane (EDPO), 6,6‐(1,2‐phenethyl)bis‐6H‐dibenz[c,e][1,2]oxaphosphorin‐6,6‐dioxide (HTP‐6123), and hexa‐phenoxy‐cyclotriphosphazene (HPCTP), were used to prepare the flame retardant diglycidyl ether of bisphenol A (DGEBA) epoxy resin (EP) under the same experimental conditions. The effects of T_g, thermal stability, and water absorption properties of EP caused by the three flame retardants were investigated and compared, together with their flame retardant efficiency. Results showed that the introduction of the three flame retardants improved the flame retardant performance of EP but led to decreases in T_g and decomposition temperature. EDPO showed higher flame retardant efficiency than the other two flame retardants. EP/EDPO showed higher thermal stability, better flame retardant performance, higher T_g value, and lower water absorption than EP/HTP‐6123 and EP/HPCTP. The study discovered that EDPO and HTP‐6123 primarily act through the gas phase flame retardant mechanism, while HPCTP is primarily driven by the condensed phase mechanism.     

Phosphorylated cellulose/Fe3+ complex: A novel flame retardant for epoxy resins

A novel flame retardant containing cellulose, phosphorus and ferrum complex (Cell‐P‐Fe) was successfully synthesized and then it was used as flame retardants in epoxy resins (EP). Due to the present of acid sources and carbon sources, the Cell‐P‐Fe exhibits improved thermal stability and flame retardant properties. The EP/Cell‐P‐Fe composites with 10 wt% of Cell‐P‐Fe show remarkably improved LOI and UL‐94 values compared with the flame retardants without ferrum. At the loading of 10.0 wt% flame retardants, the char yield for EP/Cell‐P‐Fe composites increased to 29.1 wt%, indicating the improved thermal stability at high temperature. Moreover, thermogravimetric analysis, morphology of char residues and FTIR results demonstrate that stable char layers are formed on the surface of the composites during the combustion, attributing to the catalytic carbonization effect of Fe and phosphorus and the present of cellulose as carbon source. The stable char layers, which can protect the underlying materials from heat and oxygen, play an important role in the flame retardancy enhancement.     

不饱和聚酯片状模塑料的模压成型与性能

采用模压成型的方法制备了不饱和聚酯片状模塑料(UP-SMC)制品,通过万能试验机、热重分析、动态热机械分析、氧指数和纳米压痕技术研究了制品的力学性能、热稳定性能和阻燃性能。 结果表明,UP-SMC制品的弯曲强度和冲击强度分别达到203.4和94.2 MPa,由树脂过渡到纤维的各相微观力学性能是不同的。 该制品的玻璃化转变温度为169.4 ℃,在N₂气气氛下失重5 %(T_d5)和最大失重速率(T_dmax)对应的温度分别为333.5和389.7 ℃,600 ℃的质量保留率大于75%,极限氧指数为25.7%,表明该UP-SMC制品具有优异的力学性能和热稳定性能。     

Design of aluminum trihydroxide and P‐N core‐shell structures and their synergistic effects on halogen‐free flame‐retardant polyethylene composites

In order to improve the performance of inorganic/organic composites, aluminum trihydroxide (ATH) core composites with a styrene‐ethylene‐butadiene‐styrene block copolymer grafted with maleic anhydride (MAH‐g‐SEBS) shell phase, and P‐N flame retardant as a synergistic agent, were prepared through an interface design. The effects of polyethylene glycol (PEG) content on the interfacial interaction, flame retardancy, thermal properties, and mechanical properties of high‐density polyethylene (HDPE)/ATH composites were investigated by small angle X‐ray diffraction, rotational rheometer, limiting oxygen index, thermogravimetric analysis (TGA), and tensile testing. The ATH synergistic effects of P‐N flame‐retardant improved the combustion performance of HDPE/ATH/PEG(3%)/MAH‐g‐SEBS/P‐N (abbreviated as HDPE/MH3/M‐g‐S/P‐N) composite by forming more carbon layer, increased the elongation at break from 21% to 558% compared to HDPE/ATH, and increased the interface thickness from 0.447 to 0.891 nm. SEM results support the compatibility of ATH with HDPE increased and the interfacial effect was enhanced. TGA showed the maximum decomposition temperature of the two stages and the yield of the residue at high temperature increased first and then decreased with the increase of PEG content. Rheological behavior showed the storage modulus, complex viscosity, and the relaxation time initially increased and then decreased with the increase of PEG content indicating PEG, M‐g‐S, and ATH powder gradually formed a partial coating, then a full coating, and finally an over‐coated core‐shell structured model.     

A vanillin-derived flame retardant based on 2-aminopyrimidine for enhanced flame retardancy and mechanical properties of epoxy resin

In order to give epoxy resin good flame retardance, a novel bio-based flame retardant based on 2-aminopyrimidine (referred to as VAD) was synthesized from renewable vanillin as one of the starting materials. Its structure was confirmed by NMR and mass spectra. The epoxy resins containing VAD were prepared by utilizing 4,4-diaminodiphenylmethane (DDM) as a co-curing agent, and their flame-retardant, mechanical and thermal properties and corresponding mechanisms were studied. VAD accelerated the cross-linking reaction of DDM and E51 (diglycidyl ether of bisphenol A). 12.5 wt% VAD made the epoxy resin achieve UL-94 V-0 rating and its limited oxygen index (LOI) value increase from 22.4% to 32.3%. The cone calorimetric testing results revealed the decline in the values of total heat release (THR) and peak of heat release rate (pk-HRR) and the obvious enhancement of residue yield. A certain amount of VAD enhanced the flame inhibition, charring and barrier effects, resulting in good flame retardance of the epoxy resin. Furthermore, the tensile strength, flexural strength and flexural modulus of the epoxy resin with 12.5 wt% loading of VAD were 6.5%, 14.9%, 15.2% higher than those of EP, indicating the strengthening effect of VAD. This work guarantees VAD to be a promising flame retardant for enhancing the fire retardancy of epoxy resin without compromising its mechanical properties.     

Studies on melt flow properties during capillary extrusion of PP/Al(OH)3/Mg(OH)2 flame retardant composites

The apparent melt shear viscosity of polypropylene (PP) composites filled with aluminium hydroxide (Al(OH)₃) and magnesium hydroxide (Mg(OH)₂) was measured by means of a melt flow rate instrument under experimental conditions of temperature ranging from 170 to 195 °C and load varying from 2.16 to 12.5 kg, to identify the effects of particle size and content. The results showed that the melt shear flow of the composites obeyed the power law under the experimental conditions, the dependence of the melt apparent shear viscosity (η_a) on temperature was consistent with the Arrhenius equation, and the sensitivity of the η_a for the composite melts to temperature increased with addition of flame retardant. The η_a of the composites decreased with increasing apparent shear rate. The η_a increased with an increase of the content of flame retardant, but this rate of increase decreased with a rise of temperature or load. When the particle size of flame retardant was smaller than 5 μm, the η_a of the composites increased with increase of particle size of flame retardant, and then reduced with a further increase of particle size of flame retardant.     

Effect of Phosphorus-Nitrogen Intumescent Flame Retardant on Structure and Properties of Poly(propylene)

Summary : Phosphorus-nitrogen intumescent product (R₂₀₀₀) was filled into polypropylene (PP) as a flame retardant. The neat PP and flame-retarded PP blends were studied for their structural and mechanical properties after verification of the flame retardancy character of blends. In this paper, the influence of incorporation of different amount (5%, 10%, 15%, 20%, and 25%) of R₂₀₀₀ was studied. The flame retardancy is evaluated by limiting oxygen index (LOI) value, which is enhanced from 17.5 for pure PP to 22.7 for the blend comprising 15% intumescent product, phosphorus-nitrogen based (R₂₀₀₀). The thermal degradation behaviour of the PP/R₂₀₀₀ blends was investigated using thermogravimetric analysis (TGA) under nitrogen (N₂) and oxygen (O₂) atmospheres. The influence of the R₂₀₀₀ on the PP crystallization was examined by X-ray diffraction (XRD) and differential scanning calorimetry (DSC). Further, the mechanical properties of the materials were studied by dynamic mechanical analysis (DMA). The incorporation of the flame retardant had no effect on the crystallization of the neat polymer and the mechanical properties of the materials remained unaffected.     

Synthesis and characterization of amino-terminated phosphorous polyborosiloxane and its effect on flame retardancy of polymethacrylimide

In this study, a novel flame retardant, that is, amino-terminated phosphorous polyborosiloxane (N-PBSi), was synthesized via a two-step polymerization reaction. The product's chemical structure was characterized firstly by Fourier transform infrared (FTIR) spectroscopy, nuclear magnetic resonance, and X-ray photoelectron spectroscopy. It was proved that the prepared N-PBSi was indeed amino terminated and contained multiple flame-retardant elements including P, B, and Si. Besides, based on the variation of its FTIR spectra from room temperature to 700 °C and the subsequent thermogravimetric results, there also showed that the resultant N-PBSi had desirable thermal stability. This is a prerequisite for preparing flame-retardant polymethacrylimide (PMI) as PMI synthesis requires a high temperature treatment process up to 160 °C. On this basis, the condition for N-PBSi synthesis was then optimized to obtain flame retardants with better quality and higher yield. According to the experiments, the reactant ratio and reaction time were recommended to be 1:1.33:3 and 6 h, respectively. To evaluate the effectiveness of N-PBSi further, the flame retardancy of PMI with N-PBSi grafted was then investigated. The UL-94 rating and limiting oxygen index value of the PMI with 15 wt.% of N-PBSi incorporated were tested to be V-0 and 27%, respectively, indicative of greatly enhanced flame-retardant properties. In addition, the flame-retardant mechanism of N-PBSi on PMI was also discussed. Given all of these, the prepared N-PBSi as a reactive and effective flame retardant was promising for PMI.