Effect of manganese nanoparticles on the mechanical, thermal and fire properties of polypropylene multifilament yarn

Polypropylene filled with 10 wt% of inorganic nanoparticles has been prepared by melt blending. The fillers investigated were manganese oxides (MnO and Mn₂O₃) and manganese oxalate (MnC₂O₄). The morphology and thermal stability of these nanocomposites have been studied by transmission electron microscopy (TEM) and thermogravimetric analysis (TGA). The experimental results reveal that the addition of 10 wt% manganese oxides improves the thermal stability in air of polypropylene by about 70-80 °C. In a second step, these nanocomposites have been processed by melt spinning in order to produce multifilament yarn. The mechanical properties of these filaments have then been characterized. It is shown that just the addition of Mn₂O₃ improves the mechanical properties of polypropylene filaments. The flammability of these nanocomposites used as knitted fabrics has finally been evaluated with a mass loss calorimeter at 35 kW/m². This kind of experiment has not revealed a real improvement of fire properties.     

Morphology,thermal stability,and flammability of polymer matrix composites coated with hybrid nanopapers

In this study, a hybrid nanopaper consisting of carbon nanofiber (CNF) and polyhedral oligomeric silsequioxane (POSS) or cloisite Na⁺ clay, has been fabricated through the papermaking process. The hybrid nanopaper was then coated on the surface of glass fiber (GF) reinforced polymer matrix composites through resin transfer molding (RTM) process. The morphologies of the hybrid nanopaper and resulting nanocomposites were characterized with scanning electron microscopy (SEM). It can be seen that the nanopaper had a porous structure with highly entangled carbon nanofibers and the polyester resin completely penetrated the nanopaper throughout the thickness. The thermal decomposition behavior of the hybrid nanopapers and nanocomposites was studied with the real‐time thermogravimetric analysis/ flourier transform infrared spectrometry (TGA/FTIR). The test results indicate that the addition of pristine nanoclay increased the thermal stability of the nanopaper, whereas the POSS particles decreased the thermal stability of the nanopaper. The fire retardant performance of composite laminates coated with the hybrid nanopaper was evaluated with cone calorimeter tests using a radiated heat flux of 50 kW/m². The cone calorimeter test results indicate that the peak heat release rate (PHRR) decreased dramatically in composite laminates coated with the CNF‐clay nanopaper. However, the PHRRs of the CNF‐POSS nanopaper coated composite laminates increased. The formation of compact char materials was observed on the surface of the residues of the CNF‐clay nanopaper after cone calorimeter test. The flame retardant mechanisms of the hybrid nanopaper in the composite laminates are discussed. Copyright © 2009 John Wiley & Sons, Ltd.     

Improving the mechanical properties and flame retardancy of ethylene‐vinyl acetate copolymer by introducing bis [3‐(triethoxysilyl) propyl] tetrasulfide modified magnesium hydroxide

Magnesium hydroxide (MH) was surface modified by bis [3‐(triethoxysilyl) propyl] tetrasulfide (Si‐69) in order to improve its compatibility with ethylene‐vinyl acetate (EVA) copolymer substrate. The modified MH (SMH) was then introduced to EVA through melt blending. The flammability was evaluated by limiting oxygen index (LOI), vertical burning test and cone calorimeter; 40 wt% MH/SMH will lift LOI from 17.9 in EVA to 22.3/23.3, respectively. In cone test, the peak heat release rate (PHRR) of EVA is 1382 kW/m² and reduced sharply to 601/489 kW/m² for 40 wt% MH/SMH adding, respectively. The mechanical properties were tested by a drawing machine. The elongation at break dropped almost 7 times by the addition of 40 wt% MH, from 825% in EVA dived to 124%, whereas up to 745% by the addition of 40 wt% SMH. The morphology observation by scanning electron microscopy (SEM) indicated the dispersion of surface modified MH in EVA was remarkably improved than that of MH. Copyright © 2016 John Wiley & Sons, Ltd.     

Flame retardancy of carbon nanofibre/intumescent hybrid paper based fibre reinforced polymer composites

A hybrid nanopaper consisting of carbon nanofibre (CNF) and/or clay, polyhedral oligomeric silsesquioxane (POSS), ammonium polyphosphate (APP), has been fabricated through the papermaking process. The as-prepared hybrid nanopaper was then incorporated onto the surface of glass fibre (GF) reinforced polymer matrix composites through injection moulding. The morphologies of hybrid nanopapers with and without the polymer resin were characterized with scanning electron microscopy (SEM). The polymer resin penetrated the entire nanopaper under a high-pressure compressed air system. The thermal decomposition behaviour of hybrid nanopapers infused with resin was studied with real-time thermogravimetric analysis/Fourier transform infrared spectrometry (TGA/FTIR). The test results indicate that the addition of clay in the hybrid paper increased the char residues of the nanocomposites. The fire retardant performance of composite laminates incorporating hybrid nanopaper was evaluated by cone calorimeter testing using a radiant heat flux of 50 kW/m². The cone test results indicated that the peak heat release rate (PHRR) decreased dramatically in the case of laminate composites incorporating CNF/clay/APP hybrid paper. However, the extent of reduction of PHRR of the composite laminates incorporated with CNF/POSS/APP hybrid paper was lower. The formation of compact char materials was observed on the surface of the residues and analyzed by SEM and X-ray photoelectron spectroscopy (XPS). The flame retardant mechanisms of hybrid nanopapers in composite laminates are discussed.     

Synergistic effect between a char forming agent (CFA) and microencapsulated ammonium polyphosphate on the thermal and flame retardant properties of polypropylene

The synergistic effect between a char forming agent (CFA) and microencapsulated ammonium polyphosphate (MAPP) on the thermal and flame retardancy of polypropylene (PP) are investigated by limiting oxygen index (LOI), UL‐94 test, cone calorimetry, thermogravimetric analysis (TGA), scanning electron micrograph (SEM), and water resistance test. The results of cone calorimetry show that heat release rate peak (PHRR), total heat release (THR), and the mass loss of PP with 30 wt% intumescent flame retardant (IFR, CFA/MAPP = 1:2) decreases remarkably compared with that of pure PP. The HRR, THR, and mass loss decrease, respectively from 1140 to 100 kW/m², from 96 to 16.8 MJ/m², and from 100 to 40%. The PP composite with CFA/MAPP = 1:2 has the best water resistance, and it can still obtain a UL‐94 V‐0 rating after 168 hr soaking in water. Copyright © 2008 John Wiley & Sons, Ltd.     

Chlorinated polyethylene nanocomposites using PCL/clay nanohybrid masterbatches

Exfoliated nanocomposites were prepared by dispersion of poly(ε-caprolactone) (PCL) grafted montmorillonite nanohybrids used as masterbatches in chlorinated polyethylene (CPE). The PCL-grafted clay nanohybrids with high inorganic content were synthesized by in situ intercalative polymerization of ε-caprolactone between silicate layers organo-modified by alkylammonium cations bearing two hydroxyl functions. The polymerization was initiated by tin alcoholate species derived from the exchange reaction of tin(II) bis(2-ethylhexanoate) with the hydroxyl groups borne by the ammonium cations that organomodified the clay. These highly filled PCL nanocomposites (25 wt% in inorganics) were dispersed as masterbatches in commercial chlorinated polyethylene by melt blending. CPE-based nanocomposites containing 3-5 wt% of inorganics have been prepared. The formation of exfoliated nanocomposites was assessed both by wide-angle X-ray diffraction and transmission electron microscopy. The thermal and thermo-mechanical properties were studied as a function of the filler content, by differential scanning calorimetry and dynamic mechanical analysis, respectively. The mechanical properties were also assessed by tensile tests. The Young’s modulus of CPE is increased by a decade when a PCL-grafted clay masterbatch is exfoliated to reach 5 wt% of clay in the resulting nanocomposite. The influence of PCL-grafting on the properties of these nanocomposites was investigated by comparison with materials obtained with ungrafted-PCL.     

Synergistic effects of layered double hydroxide with hyperfine magnesium hydroxide in halogen-free flame retardant EVA/HFMH/LDH nanocomposites

The synergistic effects of layered double hydroxide (LDH) with hyperfine magnesium hydroxide (HFMH) in halogen-free flame retardant ethylene-vinyl acetate (EVA)/HFMH/LDH nanocomposites have been studied by X-ray diffraction (XRD), transmission electron spectroscopy (TEM), thermogravimetric analysis (TGA), limiting oxygen index (LOI), mechanical properties' tests, and dynamic mechanical thermal analysis (DMTA). The XRD results show that the exfoliated EVA/HFMH/LDH can be obtained by controlling the LDH loading. The TEM images give the evidence that the organic-modified LDH (OM-LDH) can act as a disperser and help HFMH particles to disperse homogeneously in the EVA matrix. The TGA data demonstrate that the addition of LDH can raise 5-18 °C thermal degradation temperatures of EVA/HFMH/LDH nanocomposite samples with 5-15 phr OM-LDH compared with that of the control EVA/HFMH sample when 50% weight loss is selected as a point of comparison. The LOI and mechanical tests show that the LDH can act as flame retardant synergist and compatilizer to apparently increase the LOI and elongation at break values of EVA/HFMH/LDH nanocomposites. The DMTA data verify that the T_g value (−10 °C) of the EVA/HFMH/LDH nanocomposite sample with 15 phr LDH is much lower than that (T_g = −2 °C) of the control EVA/HFMH sample without LDH and approximates to the T_g value (−12 °C) of pure EVA, which indicates that the nanocomposites with LDH have more flexibility than that of the EVA/HFMH composites.     

Effects of melamine polyphosphate and halloysite nanotubes on the flammability and thermal behavior of polyamide 6

Melamine polyphosphate (MPP) and halloysite nanotubes (HNT) were introduced to polyamide 6 (PA6) by melt blending in order to improve the fire resistance. PA6 composite containing 12% flame retardants with good spinnability was obtained. The flammability of PA6 composite was characterized by limiting oxygen index (LOI), UL‐94 vertical burning and cone calorimeter (CONE) tests. The results indicated that the LOI value could reach 24.0 vol.% and UL‐94 rating could achieve V2 level at the presence of 12% flame retardants. CONE data demonstrated that peak heat release rate was significantly reduced from 554 kW/m² of neat PA6 to 368 kW/m² of the sample containing flame retardants. Thermal analysis indicated that the thermal stability and char formation were improved by the presence of flame retardants. The morphology of residue char was characterized by scanning electron microscopy; and it suggested that a network‐structured protective char layer had been formed. The possible synergism between MPP/HNT and their flame retardant mechanism was also analyzed and discussed. Copyright © 2014 John Wiley & Sons, Ltd.     

Synergistic effect of nanoflaky manganese phosphate on thermal degradation and flame retardant properties of intumescent flame retardant polypropylene system

Nanoflaky manganese phosphate (NMP) was synthesized from manganese nitrate and trisodium phosphate dodecahydrate, and used as a synergistic agent on the flame retardancy of polypropylene (PP)/intumescent flame retardant (IFR) system. The thermogravimetric analysis (TGA), real time Fourier-transform infrared (RTFTIR) spectroscopy measurements, cone calorimeter (CONE) and microscale combustion calorimeter (MCC) were used to evaluate the synergistic effects of NMP on PP/IFR system. When IFR + NMP was fixed at 20 wt% in flame retardant PP system, the TGA tests showed that NMP could enhance the thermal stability of PP/IFR system at initial temperature from about room temperature to 440 °C and effectively increase the char residue formation. The RTFTIR results revealed that NMP could clearly change the decomposition behavior of PP in PP/IFR system, which promotes decomposition at the initial temperature from about room temperature to 260 °C and forms more effective barrier layer to protect PP from decomposing at high temperature from about 260 °C to 500 °C. The CONE tests indicated that the addition of NMP in PP/IFR system not only reduced the peak heat release rate (HRR), but also prolonged the ignition time. The MCC results revealed that PP/IFR/NMP system generated less combustion heat over the course of heating than that of PP/IFR system. And scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) were used to explore the char residues of the PP/IFR systems with and without NMP.     

Influence of SEBS-g-MA on morphology, mechanical, and thermal properties of PA6/PP/organoclay nanocomposites

Polyamide 6/polypropylene (PA6/PP = 70/30 parts) blends containing 4 phr (parts per hundred resin) of organically modified clay (organoclay) toughened with maleated styrene-ethylene-butylene-styrene (SEBS-g-MA) were prepared by melt compounding using co-rotating twin-screw extruder followed by injection molding. X-ray diffraction (XRD) and transmission electron microscope (TEM) were used to characterize the structure of the nanocomposites. The mechanical properties of the nanocomposites were determined by tensile, flexural, and notched Izod impact tests. The single edge notch three point bending test was used to evaluate the fracture toughness of SEBS-g-MA toughened PA6/PP nanocomposites. Thermal properties were studied by using thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). XRD and TEM results indicated the formation of the exfoliated structure for the PA6/PP/organoclay nanocomposites with and without SEBS-g-MA. With the exception of stiffness and strength, the addition of SEBS-g-MA into the PA6/PP/organoclay nanocomposites increased ductility, impact strength and fracture toughness. The elongation at break and fracture toughness of PA6/PP blends and nanocomposites were increased with increasing the testing speed, whereas tensile strength was decreased. The increase in ductility and fracture toughness at high testing speed could be attributed to the thermal blunting mechanism in front of crack tip. DSC results revealed that the presence of SEBS-g-MA had negligible effect on the melting and crystallization behavior of the PA6/PP/organoclay nanocomposites. TGA results showed that the incorporation of SEBS-g-MA increased the thermal stability of the nanocomposite.     

In situ synthesis of polyethylene terephthalate nanocomposites using bis (2‐hydroxyethyl) phthalate monomer

In this article, we address in situ synthesis of polyethylene terephthalate (PET) nanocomposites using the bis (2‐hydroxyethyl) phthalate monomer and inorganic layered materials (sulfanilic acid salt‐modified magnesium aluminum‐layered double hydroxides [MgAl LDH‐SAS] and Dimethyloctadecyl [3‐(trimethoxysilyl) propyl] ammonium chloride [DTSACl] and tetraethyl orthosilicate [TEOS]‐ modified clay [CL120‐DT]). The dispersion morphology of the synthesized nanocomposites was evaluated using XRD and TEM, from these results, it was confirmed that 0.5 wt% loaded PET/MgAl LDH‐SAS and PET/CL120‐DT nanocomposites have flocculated and intercalated morphologies, respectively. Thermomechanical analyses were performed by thermogravimetric analysis, dynamic mechanical analysis, and differential scanning calorimetry, respectively. Moreover, the water vapor transmission rate (WVTR) values of a pure PET, PET/CL120‐DT 0.5 wt%, and PET/MgAl LDH‐SAS 0.5 wt% nanocomposites were found to be 49, 45, and 46 g·m^?2·day^?1, respectively. Furthermore, the gas barrier properties of PET composite films containing various amounts of inorganic nanoparticles were investigated using Gas permeability analysis (GPA).     

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.     

Effect of magnesium dihydroxide nanoparticles on thermal degradation and flame resistance of PMMA nanocomposites

The influence of magnesium dihydroxide (MDH) nanoparticles on thermal degradation and fire behavior of poly(methyl methacrylate) (PMMA) has been investigated by thermogravimetric analysis (TGA), cone calorimeter, and pyrolysis‐combustion flow calorimeter (PCFC) tests, respectively. MDH nanoparticles with either lamellar or fibrous shape have been synthesized via a sol‐gel technique and characterized by transmission electron microscopy (TEM) and X‐ray diffraction analysis. PMMA–MDH nanocomposites have been prepared by melt blending the recovered MDH nanoparticles within PMMA at different loadings (5, 10, and 20 wt% MDH). According to TGA results, the incorporation of lamellar or fibrous MDH nanoparticles into PMMA leads to a significant improvement in PMMA thermal stability, both under air and inert atmosphere. The results obtained by PCFC and cone calorimeter tests show an important decrease in the peak of heat release rate (pHRR) concomitant with charring during the combustion. Lamellar MDH nanoparticles were found to be more efficient than fibrous MDH nanoparticles. Copyright © 2010 John Wiley & Sons, Ltd.     

Lanthanum phenylphosphonate–based multilayered coating for reducing flammability and smoke production of flexible polyurethane foam

In the present work, lanthanum phenylphosphonate (LaPP)–based multilayered film was fabricated on the surface of flexible polyurethane (PU) foam by layer‐by‐layer self‐assembled method. The successful deposition of the coating was confirmed by scanning electron microscopy (SEM) and energy‐dispersive X‐ray (EDX). Subsequently, the thermal decomposition and burning behavior of untreated and treated PU foams were investigated by thermogravimetric analysis (TGA) and cone calorimeter, respectively. The TGA results indicated that T_max2 of treated PU foams were increased by approximately 15°C to 20°C as compared with untreated PU foam. The peak heat release rate (PHRR) and total heat release (THR) of PU‐6 (with 19.5 wt% weight gain) were 188 kW/m² and 20.3 MJ/m², with reductions of 70% and 15% as compared with those of untreated PU foam, respectively. Meanwhile, the smoke production of treated PU foam was suppressed after the construction of LaPP‐based coating.     

Thermal stability and fire reaction of poly(butylene succinate) nanocomposites using natural clays and FR additives

Thermal stability and fire retardancy of poly(1,4‐butanediol succinate) (PBS) nanocomposites with sepiolite and 2 halloysites was investigated using thermogravimetric analysis. Despite detrimental influence on thermal stability, confirmed by the use of isoconversional methods, nanoclays improve PBS fire behavior, studied using pyrolysis combustion flow calorimetry and cone calorimeter. Combinations of nanoclays with ammonium polyphosphate (APP) and aluminum diethyl phosphinate at 20 wt% global loading were tested using cone calorimeter at 50 kW/m². It was noticed that the formation of protective structures of metallic phosphates with APP improves fire performance. The influence of ternary compositions combining sepiolite, APP, and lignin on fire performance was investigated. The composition having equimassic loading of each component leads to strong reductions in peak of heat release rate and Maximum of Average Heat Release Evolved (MAHRE) through the formation of a cohesive protective residue, containing new types of metallic phosphates and reinforced by sepiolite particles. This composition also allows smoke release rate to be minimized.     

Synthesis and Characterization of PE-g-MA／MgAI-LDH Exfoliation Nanocomposite via Solution Intercalation

An organo‐modified MgAl‐layered double hydroxide (OMgAl‐LDH) was successfully exfoliated in the xylene solution of polyethylene‐grafted‐maleic anhydride (PE‐g‐MA) under re‐fluxing condition. A PE‐g‐MA/MgAl‐LDH exfoliation nanocomposite was formed after the precipitation of PE‐g‐MA from the dispersion system. The structure and thermal property of the PE‐g‐MA/MgAl‐LDH exfoliation nanocomposite were characterized by X‐ray diffraction (XRD), transmission electron microscopy (TEM), and thermogravimetry analysis (TGA). The disappearance of d₀₀₁ XRD peak of OMgAl‐LDH at 20 = 3.2° suggests that the MgAl hydroxide sheets are exfoliated in the nanocomposite. The TEM image shows that the MgAl hydroxide sheets of less than 70 nm in length or width are exfoliated and dispersed disorderly in PE‐g‐MA matrix. TGA profiles indicate that the PE‐g‐MA/MgAl‐LDH nanocomposite with 5 wt% OMgAl‐LDH loading shows a faster charring process in temperature range from 210 to 390 °C and a greater thermal stability beyond 390 °C than PE‐g‐MA does. The decomposition temperature of the nanocomposite is 25 °C higher than that of PE‐g‐MA as measured at 50% weight loss. The PE‐g‐MA/MgAl‐LDH nanocomposite is promising for application of flame‐retardant polymeric materials.     

A comparison of the role of boehmite (AlOOH) and alumina (Al2O3) in the thermal stability and flammability of poly(methyl methacrylate)

In this paper, a comparison of the role of boehmite (AlOOH) and alumina (Al₂O₃) in the thermal stability and flame retardant behaviour of poly(methyl methacrylate) (PMMA) is presented. PMMA–AlOOH and PMMA–Al₂O₃ nanocomposites were prepared by melt blending with different filler contents. These nanocomposites were studied by thermogravimetric analysis (TGA) and cone calorimetry. In the presence of the filler (alumina or boehmite), the thermal stability of the polymer appeared to be significantly improved. An increase of the decomposition temperature of between about 19 and 35 °C was demonstrated by TGA. Cone calorimeter measurements showed that the peak of heat release rate is lowered in the presence of AlOOH or Al₂O₃ in comparison to pure PMMA and that this decrease is higher when the filler content increases. When loading rate is higher (15 wt%), a significant improvement in fire resistance of PMMA was observed in both systems but with two different modes of action.     

Moisture Resistance,Thermal Stability and Fire Behavior of Unsaturated Polyester Resin Modified with L-histidinium Dihydrogen Phosphate-Phosphoric Acid

In this paper, the fire behavior of unsaturated polyester resin (UP) modified with L-histidinium dihydrogen phosphate-phosphoric acid (LHP), being a novel intumescent fire retardant (IFR), was investigated. Thermal and thermomechanical properties of the UP with different amounts of LHP (from 10 to 30 wt. %) were determined by thermogravimetric analysis (TG) as well as dynamic mechanical thermal analysis (DMTA). Reaction to small flames was studied by horizontal burning (HB) test, while fire behavior and smoke emission were investigated with the cone calorimeter (CC) and smoke density chamber. Further, the analysis of volatile products was conducted (TGA/FT-IR). It was observed that the addition of LHP resulted in the formation of carbonaceous char inhibiting the thermal decomposition, burning rate and smoke emission. The most promising results were obtained for the UP containing 30 wt. % of LHP, for which the highest reduction in maximum values of heat release rate (200 kW/m²) and total smoke release (3535 m²/m²) compared to unmodified polymer (792 kW/m² and 6895 m²/m²) were recorded. However, some important disadvantage with respect to water resistance was observed.     

Effects of kaolin on the thermal stability and flame retardancy of polypropylene composite

Kaolin clay was introduced into an intumescent flame retardant (IFR) system containing ammonium polyphosphate as an acid source and pentaerythritol as a carbonization agent in order to improve the thermal stability and flame retardancy of polypropylene (PP) composite. The flame retardancy and smoke suppression was evaluated by the limiting oxygen index, vertical burning UL‐94, and cone calorimeter (CONE) tests. The limiting oxygen index value was increased from 30 to 33 at the presence of 2 phr kaolin. The peak heat release rate value decreased from 1002 kW/m² of neat PP to 318 kW/m² of PP/40 phr IFR and then to 222 kW/m² of PP/38 phr IFR/2 phr kaolin. The time of the peak heat release rate was significantly prolonged after the introduction of kaolin. The morphology of char after combustion was characterized by a scanning electron microscope, and it revealed more compact char structure that was obtained at the presence of kaolin. The mechanism of kaolin on improving the retardancy and smoke suppression of PP/IFR composite was proposed on the basis of X‐ray photoelectron spectroscopy analysis. Copyright © 2014 John Wiley & Sons, Ltd.     

Fire behavior of flame retarded unsaturated polyester resin with high nitrogen content additives

The novel flame retarded unsaturated polyester resins have been developed and prepared by introduction of high nitrogen content additives into the polymer matrix in order to verify their effectiveness in the formation of swollen carbonaceous char inhibiting the burning process of the polymer. The intumescent flame retardants (IFRs) based on mixture or metal complex were developed and characterized by particle size distribution, Fourier-transform infrared spectroscopy (FTIR), nuclear magnetic resonance (NMR), powder X-ray diffraction (XRD), elemental analysis (CHN) and thermogravimetric analysis (TGA). The evaluation of the efficiency of IFRs addition on the flammability and smoke emission of the unsaturated polyester resins (UP) was carried out using the fire hazard (UL-94), limiting oxygen index (LOI) and cone calorimeter (CC) tests, as well as smoke density chamber tests. The volatile compounds evolved during the burning of materials were determined using a steady state tube furnace and a gas chromatograph with mass spectrometer. Furthermore, the prepared materials were subjected to differential scanning calorimetry (DSC), thermogravimetric analysis and water resistance tests. The mechanical properties of the materials were investigated using Shore D hardness and dynamic mechanical thermal analysis (DMA). The structural evaluation of the manufactured materials and samples after the cone calorimetry tests was carried out using scanning electron microscopy (SEM). It was found that the incorporation of new intumescent flame retardants led to the formation of carbonaceous char layers’ inhibiting the decomposition process and limiting the smoke emission. The most promising results were obtained for the resin containing complex designated as ZN3AT, for which the highest reduction in maximum values of heat release rate (419 kW/m²) compared to unmodified polymer (792 kW/m²) were recorded. Apart from that, the prepared intumescent flame retardants affect the cross-linking process as well as the thermal and mechanical properties of the UP.