Synthetic hydromagnesite as flame retardant. Evaluation of the flame behaviour in a polyethylene matrix

Synthetic hydromagnesite obtained from an industrial by-product was evaluated as a non-halogenated flame retardant. It was used in combination with aluminium hydroxide (ATH) and compared with commercial flame retardants like magnesium hydroxide (MH) and natural hydromagnesite-huntite (U) in a polyolefin system of low-density polyethylene/poly(ethylene-co-vinyl acetate) (LDPE/EVA).The thermal stability and flame behaviour of the halogen free flame retarded composites were studied by thermogravimetric and differential thermal analysis (TG-DTA), limiting oxygen index (LOI), epiradiateur and cone calorimeter. It has been shown that synthetic hydromagnesite could be an alternative solution to the use of MH in non-halogenated flame retardant systems in EVA.     

Characterization of poly(ethylene-co-vinyl acetate) (EVA) filled with low grade magnesium hydroxide

Low-grade magnesium hydroxide (LG-MH) is a solid by-product that undergoes an endothermic decomposition in the temperature range of 300-750 °C. Due to its thermal behaviour and its lower cost relative to pure Mg(OH)₂, it was studied as a non-halogenated flame retardant filler in a 28% vinyl acetate (VA) content poly(ethylene-co-vinyl acetate) matrix. The solid was characterized by XRF and the crystalline phases determined by XRD, composed predominantly of Mg(OH)₂ and calcium and magnesium carbonates. Particle size reduction was performed by both mechanical as well as air jet milling in order to optimize the particle size distribution.Composites with different filler concentrations were prepared to evaluate the mechanical properties and flame retardancy by means of limiting oxygen index tests. LOI was also determined in specimens filled with commercial flame-retardants to analyse the effectiveness of this solid.     

Thermal stability and flame retardancy of PET/magnesium salt composites

Nano-Mg(OH)₂ (nanometre magnesium hydroxide, nano-MH) was successfully introduced into the esterification and polycondensation system by in situ polymerization to obtain PET/magnesium salt composites (PETMS). The thermal properties and flame retardancy of PETMS were investigated by differential scanning calorimeter (DSC), thermogravimetric analysis (TGA), UL-94 vertical burning and limited oxygen index (LOI) test. The DSC and TGA results show that magnesium salts in the PET matrix have little effect on the thermal properties of PET, but a significant effect on the thermal stabilities of the composites. The results of LOI and UL-94 test show PETMS have higher LOI values (≥25%) and V-0 rating without melt dripping in the UL-94 test, indicating that PETMS have good flame retardancy and anti-dripping property. Moreover, the residues of magnesium salts and composites after TGA test were also studied by Fourier transform infrared spectroscopy (FTIR) to better understand the mechanism of flame retardancy, which reveals that magnesium salts accelerate the degradation of PET and catalyze the formation of char. The SEM results show the morphological structures of the char effectively protect the composites’ internal structures and inhibit the heat, smoke transmission and reduce the fuel gases when the fire contacts them.     

Study of hydromagnesite and magnesium hydroxide based fire retardant systems for ethylene-vinyl acetate containing organo-modified montmorillonite

A new flame retardant (FR) system for ethylene-vinyl acetate, mainly based on the combination of hydromagnesite (HM, obtained from an industrial by-product) and organo-modified montmorillonite (oMMT) has been compared with a magnesium hydroxide (MDH) and oMMT flame retardant system. The presence of oMMT in association with both hydrated minerals gave a strong decrease of heat release rate in cone calorimeter tests. Moreover, the HM/oMMT combination leads to a better improvement of resistance to ignition and self-extinguishability in comparison with the MDH/oMMT one. The study of residues formed during thermal decomposition revealed the formation of forsterite (Mg₂SiO₄) when either MDH or HM was used in combination with oMMT. SEM observations of residues showed sintering of the mineral particles at high temperature particularly in the case of HM/oMMT composition.     

Synergistic effect of decabromodiphenyl ethane and montmorillonite on flame retardancy of polypropylene

Polypropylene (PP) is melt-compounded in a twin-screw extruder with surface-modified decabromodiphenyl ethane/antimony trioxide (DBDPE/Sb₂O₃) and organically modified montmorillonite (OMMT). The intercalation and dispersion microstructure of OMMT in the nanocomposites are investigated by X-ray diffraction, scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Thermal stability and char residue are characterized by thermogravimetric and differential thermal analysis (TGA–DTA). Flame retardant properties are evaluated by limited oxygen index (LOI) and UL-94 vertical burning test.The results indicate that better flame retardancy can be achieved for the composite containing a modified mixture DBDPE/Sb₂O₃. The presence of DBDPE/Sb₂O₃ could improve the dispersion of OMMT in polypropylene, leading to higher thermal stability and more char residue. A synergistic effect between OMMT and DBDPE/Sb₂O₃ has been observed and discussed.     

Microhardness and thermal stability of compatibilized LDPE/PA6 blends

Microhardness tests, water absorption and thermogravimetric measurements have been performed on blends of low density polyethylene (LDPE) with different molar mass and polyamide 6 (PA6) compatibilized with 2 pph poly(ethylene-co-acrylic acid) (Escor 5001 by Exxon). The negative deviation of Vickers microhardness from the additivity has been interpreted by changes in the crystallinity of the blend components. The hardness values of the compatibilized blends that are lower than those of the corresponding uncompatibilized blends have been explained by the decrease of the degree of crystallinity of PA6 phase in the presence of Escor. The molar mass of LDPE almost does not influence on the hardness values. The lower water absorption of the compatibilized blends, caused by the formation of a copolymer between PA6 and the compatibilizer leads to microhardness values of the wet compatibilized blends higher than those of the corresponding uncompatibilized blends. The thermogravimetric measurements demonstrate that the thermal stability of blends increases in the presence of 2 pph Escor 5001. The results confirm the compatibilizing efficiency of Escor 5001 towards LDPE/PA6 blends in a wide composition range.     

Rheology and stability of bitumen/EVA blends

Rheological measurements reveal that the viscoelastic properties of a 60/70 penetration grade bitumen are improved when either a virgin EVA or a recycled EVA copolymer of similar vinyl acetate content are mixed with it. Risk of cracking at low temperatures and rutting at high temperatures, are both reduced. Better viscoelastic features are obtained with the bitumen modified with recycled EVA, probably due to the presence of carbon black, which acts like a filler in this material. Stability tests performed combining oscillatory flow and microscopy results disclose that blends with the higher polymer proportion (3%) are susceptible of phase separation after 24 h of storage at 165 °C, but 1% blends are stable for at least 4 days. A general evaluation of the results indicates that the performance of this bitumen as a binder for road pavement, is particularly improved when 1% of recycled EVA or virgin EVA is added.     

Synergistic flame retardant effects of nano-kaolin and nano-HAO on LDPE/EPDM composites

A novel flame retardant system composed of nano-kaolin and nano-HAO (nano-sized hydroxyl aluminum oxalate) was used for flame retarding the low density polyethylene (LDPE)/ethylene propylene diene rubber (EPDM) blends. Results of fire testing showed that nano-kaolin and nano-HAO exhibited excellent synergistic effects on the flame retardancy of the LDPE/EPDM composites. When 12 wt% nano-kaolin took the place of 12 wt% nano-HAO in the composites, the LOI of the composites increased from 31.0% to 35.5% and the composites could meet the UL94V-0 standard. Through thermogravimetric and differential thermal analysis (TG-DTA) it was found that nano-HAO mainly affected the degradation of the experimental composites chemically. Meanwhile, results of scanning electronic microscope (SEM) and Fourier transformation infrared spectra (FTIR) of the composites on the char layer revealed that nano-kaolin mainly affected the transfer process physically by aggregating with nano-HAO and thus the synergistic effect on flame retardancy appeared.     

LDPE/EVA/graphene nanocomposites with enhanced mechanical and gas permeability properties

In the present work, graphene oxide (GO) and reduced graphene oxide (RGO) were incorporated at low‐density polyethylene (LDPE)/ethylene vinyl acetate (EVA) copolymer blend using solution casting method. Monolayer GO with 1‐nm thickness and good transparency was synthesized using the well‐known Hummers's method. Fourier transform infrared and X‐ray photoelectron spectroscopy data exhibited efficient reduction of GO with almost high C/O ratio of RGO. Scanning electron microscopy showed the well distribution of GO and RGO within LDPE/EVA polymer matrix. The integrating effects of GO and RGO on mechanical and gas permeability of prepared films were examined. Young's modulus of nanocomposites are improved 65% and 92% by adding 7 wt% of GO and RGO, respectively. The tensile measurements showed that maximum tensile strength emerged in 3 wt% of loading for RGO and 5 wt% for GO. The measured oxygen and carbon dioxide permeability represented noticeably the attenuation of gas permeability in composite films compared with pristine LDPE/EVA blend. Copyright © 2015 John Wiley & Sons, Ltd.     

Poly(lactic acid) nanocomposites with improved flame retardancy and impact strength by combining of phosphinates and organoclay

To minimize the loading level of the char-forming phosphorus based flame retardants in the poly(lactic acid) (PLA) with reduced flammability, we have developed the flame-retarded PLA nanocomposites by melt blending method incorporating organically modified montmorillonite (OMMT) and aluminium diethylphosphinate (AlPi) additives. The influence of AlPi and OMMT on flame retardancy and thermal stability of PLA was thoroughly investigated by means of the limiting oxygen index (LOI), UL94 test, cone calorimeter, X-ray diffraction (XRD), thermogravimetric analysis and scanning electronic microscopy (SEM). The experimental results show that the PLA/AlPi/OMMT system has excellent fire retardancy. The LOI value increases from 19% for pristine PLA to 28% for the flame-retarded PLA. Cone calorimeter analysis of the PLA/AlPi/OMMT exhibits a reduction in the peak heat release rate values by 26.2%. Thermogravimetric analysis and SEM of cone calorimeter residues indicate that OMMT significantly enhances the thermal stability, promotes char-forming and suppresses the melt dripping. The research of this study implies that the combining of the flame retardant and organoclay results in a synergistic effect. In addition, the flame-retarded PLA nanocomposite also exhibits notable increase in the impact strength and the elongation at break.     

Preparation and characterization of flame retardant and low smoke releasing oil-resistant EVA/NBR blends

Nano-Si O2 and/or Mo O3 were introduced to ethylene-vinyl acetate/nitrile butadiene rubber(EVA/NBR) blends containing magnesium hydroxide(MH) and red phosphorus(RP) to further improve the mechanical properties, oil resistance, smoke suppression and flame retardancy. The results indicated that the tensile strength and oil resistance were significantly improved by incorporating nano-Si O2. Smoke suppression tests for EVA/NBR blend samples showed that both nano-Si O2 and Mo O3 can significantly reduce smoke release amount. The flammability characterization indicated that the blended sample with an LOI value of 33.0 could achieve V-0 level in the UL-94 test. Cone calorimetry test data showed the peak heat release rate was 67% lower than that for pure EVA/NBR. Thermal analysis showed that the presence of both nano-Si O2 and Mo O3 was beneficial to promoting char formation of the EVA/NBR blends. Char residual analysis suggested that Mo O3 aggregated in solid phase during combustion.     

The impact of resorcinol bis(diphenyl phosphate) and poly(phenylene ether) on flame retardancy of PC/PBT blends

Flame retardancy of bisphenol A polycarbonate (PC)/poly(butylene terephthalate) (PBT) blends was improved by the addition of resorcinol bis(diphenyl phosphate) (RDP) and poly(phenylene ether) (PPO). A PC/PBT blend at 70/30 weight ratio obtained a V‐0 rating by the addition of 10 wt% RDP and 10 wt% PPO. The combination of 5 wt% methyl methacrylate‐butadiene‐styrene tercopolymer (MBS) with 3 wt% ethylene‐butylacrylate‐glycidyl methacrylate tercopolymer (PTW) causes a remarkable increase in toughness of the PC/PBT/RDP blend while maintaining a high rigidity. A detailed investigation of the flame‐retardant action of PC/PBT/RDP and PC/PBT/RDP/PPO blends was performed using thermogravimetric analysis (TGA), Fourier transform infrared spectroscopy (FTIR), TGA‐FTIR, temperature‐programmed pyrolysis/gas chromatography/mass spectrometry (TPPy/GC/MS), and scanning electron microscopy/energy dispersive spectrometer (SEM/EDS). The results demonstrate that RDP induces a higher char yield at ca. 450 °C and synchronously increases the thermal stability of the blend with PPO. The flame‐retardant role of RDP in the condensed phase was discerned from TGA, FTIR, and SEM/EDS of the residues. Copyright © 2010 John Wiley & Sons, Ltd.     

Rheology, morphology and mechanical properties of polyethylene/ethylene vinyl acetate copolymer (PE/EVA) blends

Rheology, morphology and mechanical properties of binary PE and EVA blends together with their thermal behavior were studied. The results of rheological studies showed that, for given PE and EVA, the interfacial interaction in PE-rich blends is higher than EVA-rich blends, which in turn led to finer and well-distributed morphology in PE-rich blends. Using two different models, the phase inversion composition was predicted to be in 45 and 47 wt% of the PE phase. This was justified by morphological studies, where a clear co-continuous morphology for 50/50 blend was observed. The tensile strength for PE-rich blends showed positive deviation from mixing rule, whereas the 50/50 blend and EVA-rich blends displayed negative deviation. These results were in a good agreement with the results of viscoelastic behavior of the blends. The elongation at break was found to follow the same trend as tensile strength except for 90/10 PE/EVA blend. The latter was explained in terms of the effect of higher co-crystallization in 90/10 composition, which increased the tensile strength and decreased the elongation at break in this composition. The results of thermal behavior of the blends indicated that the melting temperatures of PE and EVA decrease and increase, respectively, due to the dilution effect of EVA on PE and nucleation effect of PE on EVA.     

Effect of montmorillonite and chain extender on rheological,morphological and biodegradation behavior of PLA/PBAT blends

The effect of montmorillonite clay (MMT) and/or chain extender (CE) on rheological, morphological and biodegradation properties of PLA/PBAT blend was investigated. The biodegradation behavior was evaluated by CO₂ evolution in soil burial. CE incorporation resulted in an increase in the complex viscosity of PLA/PBAT blends, an increase in PLA crystallinity and a decrease in the dispersed phase diameter. MMT incorporation resulted in an increase in the complex viscosity, more pronounced shear-thinning behavior and a decrease in the dispersed phase diameter. CE incorporation resulted in a slight effect in the rheological properties of PLA/PBAT blend in the presence of MMT. Unfilled PLA/PBAT blend presented the highest amount of evolved CO₂, and the micrographs indicated that degradation tends to occur on the surface. MMT delayed biodegradation of PLA/PBAT blends even although their surfaces presented some cracks and holes in a few localized regions. PLA/PBAT + CE blend presented the lowest amount of evolved CO₂.     

Flame retardancy and flame retarding mechanism of high performance hyperbranched polysiloxane modified bismaleimide/cyanate ester resin

A novel kind of modified bismaleimide/cyanate ester (BCE) resins by copolymerizing with hyperbranched polysiloxane including high content of phenyl (HBPSi) was first reported. The effect of HBPSi on the curing mechanism, and that on the dielectric properties and flame retardancy of cured networks were systemically investigated. Results show that compared with BCE resin, HBPSi/BCE resin has obviously different cross-linked structure, and thus leading to simultaneously improved dielectric properties and flame retardancy. The reactions between HBPSi and the decomposition structure of BCE resin change the thermo-oxidative degradation mechanism of the first step in the thermo-oxidative degradation; in addition, the presence of HBPSi in BCE resin also significantly reduces the mass loss rate (MLR) and increases char yield at 800 °C under an air atmosphere. Therefore, the positive effect of HBPSi on improving the flame retardancy is attributed to the condensed phase mechanism. On the other hand, HBPSi/BCE resins exhibit improved dielectric properties (including decreased dielectric constant and loss) with increasing the content of HBPSi. More importantly, this investigation demonstrates that designing new polysiloxane with suitable chemical structure is important to develop high performance resins with attractive flame retardancy and dielectric properties.     

Tensile and flexural properties of polypropylene composites filled with highly effective flame retardant magnesium hydroxide

The reinforcing effects of highly effective flame retardant magnesium hydroxide (FMX) content on the tensile and flexural properties of filled polypropylene (PP) composites were investigated within the FMX weight fraction range from 5 to 60 wt%. It was found that the Young's modulus and flexural modulus increased approximately linearly while the tensile yield strength and tensile fracture strength decreased slightly with increasing the FMX weight fraction. When the FMX weight fraction was lower than 20%, the tensile elongation at break decreased considerably, and then decreased slightly; the flexural strength increased when the FMX weight fraction was lower than 30%, and then decreased slightly. The tensile properties increased with increasing rate of tension. Moreover, the tensile yield strength of the composites was estimated using an equation proposed in previous work, and good agreement was shown between the predicted and the measured data.     

Synergistic effects and mechanism of multiwalled carbon nanotubes with magnesium hydroxide in halogen-free flame retardant EVA/MH/MWNT nanocomposites

The synergistic effects and mechanism of multiwalled carbon nanotubes (MWNTs) with magnesium hydroxide (MH) in halogen-free flame retardant EVA/MH/MWNT nanocomposites have been studied by cone calorimeter test (CCT), limiting oxygen index (LOI), thermogravimetric analysis (TGA), torque test, morphological evolution experiment, and scanning electron microscopy (SEM). The data obtained from the CCT, LOI, and TGA show that suitable amount of MWNTs has synergistic effects with MH in the EVA/MH/MWNT nanocomposites. The MWNTs can considerably decrease the heat release rates and mass loss rate by about 50-60%, prolongate the combustion time to near two times, and increase the LOI values by 5% when 2 wt% MWNTs substitute for the MH in the EVA/MH/MWNT samples. The TGA data also show that the synergistic effects of MWNTs with MH apparently increase the thermal degradation temperatures and final charred residues of the EVA/MH/MWNT samples. The experimental observations from the torque, morphological evolution tests, and SEM give positive evidences that the synergistic mechanism of MWNTs with MH can be described to: (i) the increase of melt viscosity because of network structure formation of MWNTs in the EVA/MH matrix; (ii) the enhancement of thermo-oxidation stability due to the MWNTs' mechanical strength and integrity of the charred layers in the EVA/MH/MWNT nanocomposites; (iii) the formation of compact charred layers promoted by MWNTs acted as heat barrier and thermal insulation. All the above-mentioned factors efficiently enhance thermal and flame retardant properties and protect the EVA/MH/MWNT nanocomposite materials to be burning.     

Thermal stability and flammability characteristics of ethylene vinyl acetate (EVA) composites blended with a phenyl phosphonate-intercalated layered double hydroxide (LDH), melamine polyphosphate and/or boric acid

A phenyl phosphonate-intercalated MgAl-LDH (MgAl-PPh), melamine polyphosphate (MP), and boric acid (BA) were independently and concomitantly added to neat ethylene vinyl acetate (EVA) copolymer at loading fractions of 10% (w/w). The structural morphology of MgAl-PPh was established via powder X-ray diffraction (PXRD) and scanning electron microscopy (SEM) while the presence of phenyl phosphonate in the galleries was confirmed by Fourier transform infrared (FTIR). Thermogravimetric analysis (TGA) and cone calorimetry were used to evaluate the thermal stability and flammability behavior of EVA and its composites. While time-to-ignition is greatly reduced for EVA composites compared to the virgin polymer, there are remarkable reductions in the peak heat release rate (PHRR) which relates to a reduction in flame intensity. Synergistic effects were observed in cone calorimetry for the formulation containing MgAl-PPh, MP, and BA.