Thermal degradation behaviors of epoxy resin/POSS hybrids and phosphorus–silicon synergism of flame retardancy

Epoxy resin (EP)/polyhedral oligomeric silsesquioxane (POSS) hybrids were prepared based on octavinyl polyhedral oligomeric silsesquioxane (OVPOSS) and phosphorus‐containing epoxy resin (PCEP). The PCEP was synthesized via the reaction between bisphenol A epoxy resin (DGEBA) and 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO). The structure and morphology of PCEP/OVPOSS hybrids were characterized by Fourier transform infrared spectroscopy and transmission electron microscopy. Differential scanning calorimetry revealed that the PCEP/OVPOSS hybrids possessed higher glass transition temperatures than that of PCEP. The thermal stability of the PCEP/OVPOSS hybrids was studied using thermogravimetric analysis (TGA). The TGA results illustrated the synergistic effect of phosphorus–silicon of flame retardancy: phosphorus promotes the char formation, and silicon protects the char from thermal degradation. The thermal degradation mechanism of the PCEP/OVPOSS hybrids was investigated by real time Fourier transform infrared spectra and pyrolysis/gas chromatogram/mass spectrometry (Py‐GC/MS) analysis. It was found that OVPOSS migrated to the surface of the matrix and then sublimed from the surface in nitrogen; whereas, the vinyl groups of OVPOSS were oxidated to form a radical trap which could react with pyrolysis radicals derived from PCEP to form the branched and crosslinked structure in air. The combustion behaviors of the hybrids were evaluated by micro combustion calorimetry. The addition of OVPOSS obviously decreased the value of peak heat release rate and total heat release of the hybrids. Moreover, scanning electron microscopy (SEM) and X‐ray photoelectron spectroscopy were used to explore the char residues of the PCEP and the hybrids. © 2010 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 48: 693–705, 2010     

Synthesis,Characterization of Phosphorus ContainingDiamide-diimide-tetraamines Based on L-TryptophanAmino Acid and Their Effect on Flame Retardancy ofEpoxy Resins简

The curing behavior of diglycidyl ether of bisphenol-A(DGEBA) with different phosphorus containing diamidediimide-tetraamines(DADITAs) was studied by DSC. Eight DADITAs of varying structures were synthesized by reacting 1 mole of pyromellitic anhydride(PMDA)/3,3′-benzophenone tetracarboxylic dianhydride(BTDA)/1,4,5,8-naphthalene tetracarboxylic dianhydride(NTDA)/4,4′-oxydiphthalic anhydride(ODPA) with 2 mole of L-tryptophan(T) in a mixture of acetic acid and pyridine(3:2 V/V) followed by activaton with thionyl chloride and then condensation with excess of phosphorus containing triamines tris(3-aminophenyl) phosphine(TAP) and tris(3-aminophenyl) phosphine oxide(TAPO). DADITAs obtained by reacting PMDA/BTDA/NTDA/ODPA with L-tryptophan followed by condensation with TAP/TAPO were designated as PTAP, PTAPO, BTAP, BTAPO, NTAP, NTAPO, OTAP and OTAPO respectively. The structural characterization of synthesized DADITAs was done by FTIR,1H-NMR,13C-NMR,31P-NMR spectroscopic techniques and elemental analysis. Thermal stability of the isothermally cured epoxy was investigated using dynamic thermogravimetry analysis. The glass transition temperature(Tg) was highest in DGEBA cured using PTAP. All epoxy thermosets exhibited excellent flame retardancy, moderate changes in Tg and thermal stability. Due to presence of phosphorus in curing agents, all epoxy resin systems met the UL-94 V-0 classification and the limiting oxygen index(LOI) reached up to 38.5, probably because of the nitrogen-phosphorus synergistic effect.     

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.     

New star‐shaped phosphorus‐containing flame retardants based on acrylates for epoxy resins

New star‐shaped phosphorus‐containing flame retardants were synthesized by phospha‐Michael‐addition of diphenylphosphine oxide and dimethyl phosphite to oligofunctional acrylates. The products were examined via UL 94 V‐rating and thermogravimetric analysis in three different epoxy resin systems compared to the recently described correspondent derivatives based on the phosphinate‐type 6‐oxido‐6H‐dibenzo[c,e][1,2]oxaphosphinine. The influence of a systematically altered chemical environment of the phosphorus atom on the flame retardancy and the char yield was investigated. Furthermore, the glass transition temperatures of the modified resins were studied via differential scanning calorimetry, including the deviation after an additional treatment at elevated temperature. Copyright © 2013 John Wiley & Sons, Ltd.     

Silicon-containing flame retardant epoxy resins: Synthesis, characterization and properties

Epoxy resins with different silicon contents were prepared from silicon-containing epoxides or silicon-containing prepolymers by curing with 4,4′-diaminodiphenylmethane. The reactivity of the silicon-based compounds toward amine curing agents was higher than that of the conventional epoxy resins. The T_g of the resulting thermosets was moderate and decreased when the silicon content increased. The onset decomposition temperatures decreased and the char yields increased when the silicon content increased. Epoxy resins had a high LOI value, according to the efficiency of silicon in improving flame retardance.     

Studies on thermal degradation of acrylonitrile–butadiene–styrene copolymer (ABS-Br) containing brominated flame retardant

The thermal degradation of acrylonitrile-butadiene-styrene copolymer (ABS-Br; 10 g) containing brominated flame retardant (Br: 9.59 wt.%) was carried out at 450 °C using a semi batch operation using two different temperature programs. The heating rate was found to affect the quality of the degradation oil and yield of products (liquid, gas and residue). Data on the effect of the temperature program on the accumulation of liquid products was presented. It was found that the majority of the bromine was concentrated in the carbon residue and while majority of the nitrogen accumulates in the liquid products irrespective of degradation mode. The use of a one step constant heating rate process (I) produced a higher liquid yield (39%), than a two step process (29%). Differences were also noted in the Br and N contained in the liquids produced by the two processes.     

Synthesis, application and flame retardancy mechanism of a novel flame retardant containing silicon and caged bicyclic phosphate for polyamide 6

A novel flame retardant containing silicon and caged bicyclic phosphate groups, tri(2,6,7-trioxa-1-phosphabicyclo[2.2.2]octane-1-oxo-4-hydroxymethyl) phenylsilane (TPPSi) was successfully synthesized. The chemical structure of TPPSi was characterized by FTIR, ¹H NMR and ³¹P NMR. The application of TPPSi (25 wt%) as a flame retardant in polyamide 6 (PA6) not only gains satisfied flame retardancy and smoke suppression, but also retains the high toughness and inherent appearance of pure PA6. The influence of TPPSi on the decomposition pathway of PA6 was discussed based on TG-FTIR and FTIR analysis. The interaction between TPPSi and PA6 at high temperature alters the decomposition pathway of PA6 resulting in the formation of the residue containing phosphorus and silicon. The heat and smoke release behaviors at different external heat fluxes were measured by cone calorimeter, and the fire residue was analyzed by SEM-EDX. The condensed phase action resulting from the barrier effect of residue is proposed to be the major flame retardancy mechanism of TPPSi in PA6, with the fuel reduction action as the minor.     

The effect of nanoparticles on structural morphology, thermal and flammability properties of two epoxy resins with different functionalities

The effect of layered silicate nanoclays, nano-silica and double-walled carbon nanotubes (DWNTs) on the thermal stability and fire reaction properties of two aerospace grade epoxy resins (a high temperature curing tetra-functional and a low temperature curing bi-functional resin) has been investigated using thermal analysis, cone calorimetry, LOI and UL-94 techniques. The morphology of the polymer-clay nanocomposites, determined by X-ray diffraction and transmission electron microscopy indicated intercalated structures. The addition of nanoclays (5-wt%) to both resins had a thermal destabilisation effect in the low temperature regime (<400 °C), but led to higher char yield at higher temperatures. The inclusion of nano-silica at 30-wt% significantly improved the thermal stability of the resins while DWNTs had an adverse effect due to their poor dispersion in the matrix. The nanoclays and carbon nanotubes significantly increased the fire resistance of the tetra-functional epoxy resin while a minimal effect was observed for the bi-functional resin.     

Synergistic effect of ferric chloride and silicon mixtures on the thermal stabilization enhancement of ABS

A previous study from this laboratory has shown that Lewis acid-type transition metal chlorides (NiCl₂, CoCl₂, ZnCl₂, and FeCl₃) are effective char forming catalysts for ABS terpolymer in an inert atmosphere [Jang J, Kim JH, Bae JY. Polym Degrad Stab 2005;88(2):324.]. However, transition metal chloride catalysed char formation (and flame-retardance enhancement) of ABS in air was unsuccessful due to the oxidative degradation of the char at a higher temperature. In order to overcome these undesirable phenomena, we incorporated silicon with transition metal chlorides as co-catalyst and a series of ABS/transition metal chloride/silicon compounds were made from them and their flame retardancy was evaluated by measuring the limiting oxygen index (LOI) values. Our results showed that among various transition metal chloride/silicon catalyst systems the incorporated mixture of ferric chloride and silicon is very effective in enhancing the thermal stabilization of ABS and LOI value as high as 33 is obtained. The reason for this synergistic effect by ferric chloride and silicon was postulated to come from the interaction between ferric chloride and silicon at elevated temperatures, probably generating silicon tetrachloride and hydrogen chloride.     

Metal compound-enhanced flame retardancy of intumescent epoxy resins containing ammonium polyphosphate

A series of intumescent flame-retardant epoxy resins (IFR-EPs) were prepared only by adding a 5 wt% total loading of ammonium polyphosphate (APP) and metal compounds. All the samples could achieve V-0 rating and did not generate dripping during UL-94 testing. The limiting oxygen index (LOI) values of the samples with 4.83 wt% APP and 0.17 wt% CoSA increase from 27.1 to 29.4, compared with epoxy resin containing 5 wt% APP. The samples also showed excellent water resistance of flame retardancy in 30 °C and 70 °C water for 168 h. The LOI results show that the composition of metal compounds (metal ions and ligands/anions) and the mass ratios of APP to metal compounds affect the flame retardancy of the samples. TG results indicate that the catalytic effect of CoSA on the decomposition of both APP and the epoxy resins containing APP is better than that of CuSAO. The fire behavior of epoxy resin and epoxy resins containing APP with/without CoSA were investigated by cone calorimeter. Cone calorimeter parameters of the samples such as HRR, THR, TSP and COP indicate that the addition of APP and CoSA improves the fire safety of epoxy resin significantly, and CoSA shows an obvious catalytic effect.     

Facile synthesis of bio-based phosphorus-containing epoxy resins with excellent flame resistance

The development of high-performance biomass-derived epoxy thermosets with excellent flame resistance is vital to various applications (i.e., composites, coatings and adhesives). Herein, a difunctional epoxy monomer bis(2-methoxy-4-(oxiran-2-ylmethyl)phenyl) phenyl phosphate (BEU-EP) was synthesized from abundant and biobased eugenol. In addition, BEU-EP was cured by 4,4′-diaminodiphenyl methane (DDM) and the cured resin diglycidyl ether of bisphenol A (DGEBA)/DDM was used as a reference. Results indicated that BEU-EP/DDM not only showed a 58.1%, 28.8% and 35.1% increase in residual char (at 700 °C), flexural and storage modulus (at 30 °C) compared with DGEBA/DDM, but also exhibited excellent flame resistance and smoke suppression. BEU-EP/DDM passed V-0 rating (in UL-94 testing) with limiting oxygen index (LOI) of 38.4% and greatly decreased the peak heat release rate (pHRR) and total smoke production (TSP) by 84.9% and 80.5%, respectively. The mechanism analysis confirmed that the phosphorus-containing group and aromatic structure from BEU-EP contributed both the gas and condensed-phase flame retardation of BEU-EP/DDM network. This work provides an efficient and scalable route for synthesizing biobased epoxy thermosets with high integrated performance and superior flame resistance.     

Curing studies of epoxy resins with phosphorus‐containing amines

The curing system of diglycidyl ether of bisphenol A (DGEBA) with two phosphorus‐containing amine compounds—bis(3‐aminophenyl)methyl phosphine oxide and bis(4‐aminophenyl)‐bis(9,10‐dihydro‐9‐oxa‐10‐oxide‐10‐phosphaphenanthrene‐10‐yl)methane—was studied with differential scanning calorimetry under isothermal and nonisothermal conditions and compared with the DGEBA/diamino diphenyl methane system. The isoconversional method was used to evaluate the dependence of the effective activation energy on the extent of conversion. Modulated differential scanning calorimetry and dynamic mechanical thermal analysis were used to study the phenomena of vitrification and gelation. The thermal and flame‐retardant properties were evaluated, and the limiting oxygen index values of the phosphorylated resins, above 30, confirmed that phosphorus‐containing epoxy resins are effective flame retardants. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1676–1685, 2006     

Blowing‐out effect and temperature profile in condensed phase in flame retarding epoxy resins by phosphorus‐containing oligomeric silsesquioxane

A series of flame retardant epoxy resins (EPs) containing phosphorus‐containing oligomeric silsesquioxane are prepared, and an interesting blowing‐out effect is detected in flame retardant EPs. The temperature profiles show that blowing‐out effect slows the heat transfer from the fire to the unburned matrix; furthermore, this blowing‐out effect can even take away some heat from the surface zone by the spurting gases. The thermo gravimetric analyzer and Fourier transform infrared spectrometer result shows that the spurting gases during the blowing‐out effect have a high content of CO₂, which could reduce the combustion capability of the jetting gases. The flame retardancy of these EPs is tested by limit oxygen index and UL‐94. The incorporation of 2.5 wt% phosphorus‐containing oligomeric silsesquioxane into EP gives a remarkable blowing‐out effect, which results in a significant enhancement of limit oxygen index value and UL‐94 rating. The flame retardancy mechanism of blowing‐out effect is quite different from the traditional mechanisms. The char strength and morphology of EP composites are also investigated to explain the mechanism of the blowing‐out effect. Copyright © 2013 John Wiley & Sons, Ltd.     

Synthesis of three novel phosphorus-containing flame retardants and their application in epoxy resins

One symmetric diamine (4) and two symmetric phenols (5) and (6) were synthesized as phosphorus-containing flame retardants. The synthesis comprised a two-step procedure: the condensation of p-phenylenediamine with benzaldehyde, 4-hydroxybenzaldehyde and 2-hydroxybenzaldehyde respectively, followed by the addition of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide to the imine linkage. The structures of (4)-(6) were characterized by FTIR, NMR and mass spectra. (4)-(6) served as co-curing agents of diaminodiphenylmethane for epoxy resins, and epoxy thermosets exhibited excellent flame retardancy, moderate changes in glass transition temperature (T_g) and thermal stability. When the phosphorus content reached 1.0 wt.%, the epoxy resin system met the UL-94 V-0 classification and the limiting oxygen index (LOI) reached more than 35.6, probably because of the nitrogen-phosphorus synergistic effect.     

Preparation, thermal properties and flame retardancy of phosphorus- and silicon-containing epoxy resins

Phosphorus- and silicon-containing epoxy resins were prepared from (2,5-dihydroxyphenyl)diphenyl phosphine oxide (Gly-HPO), diglycidyloxy methylphenyl silane (DGMPS) and 1,4-bis(glycidyloxydimethyl silyl)-benzene (BGDMSB) as epoxy monomers and diaminodiphenylmethane (DDM), bis(3-aminophenyl)methyl phosphine oxide (BAMPO) and bis(4-aminophenoxy)dimethyl silane (APDS) as curing agents. Epoxy resins with different phosphorus and silicon content were obtained. Their thermal, dynamic mechanical and flame retardant properties were evaluated. The high LOI values confirmed that epoxy resins containing hetero-atoms are effective flame retardants, but a synergistic efficiency of phosphorus and silicon on flame retardation was not observed.     

Flame-retardant effect of a functional DOPO-based compound on lignin-based epoxy resins

A simple and environmentally benign synthetic route to lignin-based epoxy resins is highly desirable. Alkali lignin and glyoxal are promising renewable and sustainable alternatives to phenol and formaldehyde, respectively. Their use is demonstrated to produce lignin-phenol-glyoxal novolac epoxy resins (LPG-NERs) through a simple one-pot synthesis. Flame retardancy of LPG-NERs was improved by functionalization with a N, S modified 9, 10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) material (termed DBS) obtained via nucleophilic reaction between DOPO and a N, S containing intermediate. FTIR and ¹H NMR analyses confirmed the successful fabrication of LPG-NERs and SBD. The introduction of lignin and SBD reduced crosslinking of the epoxy network, weakening mechanical properties, but conferred excellent flame retardancy (including vapor and condensed phases) as determined by LOI (34.5%), UL-94 (V-0 rating), and cone calorimetry tests (lower heat release and smoke production, and higher char formation). The SBD structure imparted a desirable vapor mechanism (blowing out phenomenon caused by the fire quenching effect of PO?/PO₂? radicals and dilution effect from non-condensable gases such as NH₃, N₂, SO₂), while lignin (a natural biochar precursor) in synergy with SBD imparted superior charring performance.     

Kinetics study of thermal decomposition of epoxy resins containing flame retardant components

Hyperbranched polyphosphate ester (HPPE) and phenolic melamine (PM) were blended in different ratios with a commercial epoxy resin to obtain a series of flame retardant resins. The thermal decomposition mechanism of their cured products in air was studied by thermogravimetric analysis and in situ Fourier-transform infrared spectroscopy. The degradation behaviours of epoxy resins containing various flame retardant components were found to be greatly changed. The incorporation of phosphorus and nitrogen compounds improved the thermal stability at elevated temperature. The kinetics of thermal decomposition was evaluated by Kissinger method, Flynn-Wall-Ozawa method and Horowitz-Metzger method. The results showed that the activation energy at lower degree of the degradation decreased by the incorporation of flame retardant components, while increased at higher degree of the degradation.     

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     

Photopolymerization and thermal behaviors of acrylated benzenephosphonates/epoxy acrylate as flame retardant resins

Di(acryloyloxyethyl) benzenephosphonate (DABP) and acryloyloxyethyl phenyl benzenephosphonate (APBP) were synthesized starting from phenylphosphonic dichloride, and characterized by FT-IR and ¹H NMR. DABP and APBP were blended in the ratios of 10-50 wt.% with a commercial epoxy acrylate oligomer (EB600) to obtain a series of flame retardant UV-curable formulations. The viscosity of the formulations greatly reduced by the addition of the reactive monomers, whereas the photopolymerization rate according to the photo-DSC analysis increased. The thermal degradation behavior and flame retardancy of the UV-cured films were investigated by thermogravimetric analysis and the limiting oxygen index (LOI). The results revealed that the blended epoxy acrylates with DABP or APBP possess improved thermal stability at elevated temperature and have higher char yields, together with higher LOI values. The data from dynamic mechanical thermal analysis showed that DABP and APBP have good miscibility with EB600. The crosslink density increased along with the content of DABP or APBP in the blend, whereas the glass-transition temperatures of the blended resins decreased compared to pure cured EB600.