Thermal degradation and flame retardancy of epoxy resins containing intumescent flame retardant

Pentaerythritol diphosphonate melamine-urea-formaldehyde resin salt, a novel cheap macromolecular intumescent flame retardants (IFR), was synthesized, and its structure was a caged bicyclic macromolecule containing phosphorus characterized by IR. Epoxy resins (EP) were modified with IFR to get the flame retardant EP, whose flammability and burning behavior were characterized by UL 94 and limiting oxygen index (LOI). 25 mass% of IFR were doped into EP to get 27.2 of LOI and UL 94 V-0. The thermal properties of epoxy resins containing IFR were investigated with thermogravimetry (TG) and differential thermogravimetry (DTG). Activation energy for the decomposition of samples was obtained using Kissinger equation. The resultant data show that for EP containing IFR, compared with EP, IFR decreased mass loss, thermal stability and R _max, increased the char yield. The activation energy for the decomposition of EP is 230.4 kJ mol⁻¹ while it becomes 193.8 kJ mol⁻¹ for EP containing IFR, decreased by 36.6 kJ mol⁻¹, which shows that IFR can catalyze decomposition and carbonization of EP.     

Effect of a triazine ring‐containing charring agent on fire retardancy and thermal degradation of intumescent flame retardant epoxy resins

A triazine ring‐containing charring agent (PEPATA) was synthesized via the reaction between 2,6,7‐trioxa‐l‐phosphabicyclo‐[2.2.2]octane‐4‐methanol (PEPA) and cyanuric chloride. It was applied into intumescent flame retardant epoxy resins (IFR‐EP) as a charring agent. The effect of PEPATA on fire retardancy and thermal degradation behavior of IFR‐EP system was investigated by limited oxygen index (LOI), UL‐94 test, microscale combustion calorimetry (MCC), thermogravimetric analysis (TGA) and thermogravimetric analysis/infrared spectrometry (TG‐IR). The glass transition temperatures (T_g) of IFR‐EP systems were studied by dynamic mechanical analysis (DMA). The LOI values increased from 21.5 for neat epoxy resins (EPs) to 34.0 for IFR‐EP, demonstrating improved flame retardancy. The TGA curves showed that the amount of residue of IFR‐EP system was largely increased compared to that of neat EP at 700 °C. The new IFR‐EP system could apparently reduce the amount of decomposing products at higher temperatures and promotes the formation of carbonaceous charred layers that slowed down the degradation. Copyright © 2010 John Wiley & Sons, Ltd.     

Flame retardant epoxy resins based on diglycidyloxymethylphenylsilane

Silicon‐containing epoxy resins were prepared from diglycidyloxymethylphenyl silane (DGMPS) and diglycidylether of bisphenol A (DGEBA) by crosslinking with 4,4′‐diaminodiphenylmethane (DDM). Several DGMPS/DGEBA molar ratios were used to obtain materials with different silicon contents. Their thermal, dynamomechanical, and flame‐retardant properties were evaluated and related to the silicon content. The weight loss rate of the silicon‐containing resins is lower than that of the silicon free resin. Char yields under nitrogen and air atmospheres increase with the silicon content. The LOI (limited oxygen index) values increased from 24 for a standard commercial resin to 36 for silicon‐containing resins, demonstrating improved flame retardancy. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 5580–5587, 2006     

Thermal stability of microencapsulated epoxy resins with poly(urea-formaldehyde)

A series of microcapsules filled with epoxy resins with poly(urea-formaldehyde) (PUF) shell were synthesized by in situ polymerization, and they were heat-treated for 2 h at 100 °C, 120 °C, 140 °C, 160 °C, 180 °C and 200 °C. The effects of surface morphology, wall shell thickness and diameter on the thermal stability of microcapsules were investigated. The chemical structure and surface morphology of microcapsules were investigated using Fourier-transform infrared spectroscope (FTIR) and scanning electron microscope (SEM), respectively. The thermal properties of microcapsules were investigated by thermogravimetric analysis (TGA and DTA) and by differential scanning calorimetry (DSC). The thermal damage mechanisms of microcapsules at lower temperature (<251 °C) are the diffusion of the core material out of the wall shell or the breakage of the wall shell owing to the mismatch of the thermal expansion of core and shell materials of microcapsules. The thermal damage mechanisms of microcapsules at higher temperature (>251 °C) are the decomposition of shell material and core materials. Increasing the wall shell thickness and surface compactness can enhance significantly the weight loss temperatures (T_d) of microcapsules. The microcapsules with mean wall shell thickness of 30 ± 5 μm and smoother surface exhibit higher thermal stability and can maintain quite intact up to approximately 180 °C.     

Thermal and electrical behavior of hybrid thermosets based on epoxy and maleimide resins cured with p-aminobenzoic acid

Two thermoset systems based on maleimides and diglycidyl ether of bisphenol A (DGEBA) cured with p-aminobenzoic acid were characterized in terms of thermal and electrical behavior. Thermal characterization has been undertaken by means of thermogravimetric analysis in nitrogen atmosphere up to 600°C using simultaneous thermogravimetric/Fourier transform infrared/mass spectrometry (TG/FT-IR/MS) analysis. In the first stage of thermal degradation, the global kinetic parameters [activation energy (E_a) and preexponential factor (log A₁ (s⁻¹))] were calculated using the isoconversional method of Friedman. The energies variation as well as the shape of the differential thermal analysis curves suggests that the thermal decomposition process occurred in multiple stages. The evolved gases analysis was conducted by simultaneous TG/FT-IR/MS coupled techniques. Dielectric relaxation spectroscopy characterization was also made.     

Flame‐retardant epoxy resins from o‐cresol novolac epoxy cured with a phosphorus‐containing aralkyl novolac

A novel phosphorus‐containing aralkyl novolac (Ar‐DOPO‐N) was prepared from the reaction of 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO) first with terephthaldicarboxaldehyde and subsequently with phenol. The chemical structures of the synthesized compounds were characterized with Fourier transform infrared, ¹H and ³¹P NMR, and elemental analysis. Ar‐DOPO‐N blended with phenol formaldehyde novolac was used as a curing agent for o‐cresol formaldehyde novolac epoxy, resulting in cured epoxy resins with various phosphorus contents. The epoxy resins exhibited high glass‐transition temperatures (159–177 °C), good thermal stability (>320 °C), and retardation on thermal degradation rates. High char yields and high limited oxygen indices (26–32.5) were observed, indicating the resins' good flame retardance. Using a melamine‐modified phenol formaldehyde novolac to replace phenol formaldehyde novolac in the curing composition further enhanced the cured epoxy resins' glass‐transition temperatures (160–186 °C) and limited oxygen index values (28–33.5). © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 2329–2339, 2002     

Preferential melt intercalation of clay in ABS/brominated epoxy resin-antimony oxide (BER-AO) nanocomposites and its synergistic effect on thermal degradation and combustion behavior

ABS/organo montmorillonite (OMT) nanocomposites and ABS/brominated epoxy resin-antimony oxide (BER-AO)/OMT nanocomposites were prepared via melt compounding. The dispersion of OMT in nanocomposites was investigated by wide-angle X-ray diffraction and transmission electron microscopy. The results revealed an intercalated structure in ABS/OMT nanocomposites and the OMT layers mainly distribute in SAN phase. However, a completely exfoliated structure was found in ABS/BER-AO/OMT nanocomposites and OMT layers preferentially located in the BER phase which indicated that the OMT platelets had a much higher affinity with brominated epoxy resin than ABS resin. Based on the above morphological results, a schematic diagram of the ABS/OMT, ABS/BER-AO/OMT nanocomposites was established. The thermal degradation behavior was characterized by thermogravimetry. The results showed that the exfoliation of OMT can enhance the thermal stability of pure ABS resin and ABS/BER blends. An increase in the limited oxygen index (LOI) value was observed with the addition of OMT and it was found that such an enhancement is closely related to the morphologies of the chars formed after combustion. A synergistic effect between OMT and BER-AO during the combustion of the nanocomposites was found and a schematic mechanism was presented.     

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     

Synthesis and thermal characterization of phosphorus containing siliconized epoxy resins

Siliconized epoxy matrix resin was developed by reacting diglycidyl ethers of bisphenol A (DGEBA) type epoxy resin with hydroxyl terminated polydimethylsiloxane (silicone) modifier, using γ-aminopropyltriethoxysilane crosslinker and dibutyltindilaurate catalyst. The siliconized epoxy resin was cured with 4, 4-diaminodiphenylmethane (DDM), 1,6-hexanediamine (HDA), and bis (4-aminophenyl) phenylphosphate (BAPP). The BAPP cured epoxy and siliconized epoxy resins exhibit better flame-retardant behaviour than DDM and HDA cured resins. The thermal stability and flame-retardant property of the cured epoxy resins were studied by thermal gravimetric analysis (TGA) and limiting oxygen index (LOI). The glass transition temperatures (T_g) were measured by differential scanning calorimetry (DSC) and the surface morphology was studied by scanning electron microscopy (SEM). The heat deflection temperature (HDT) and moisture absorption studies were carried out as per standard testing procedure. The thermal stability and flame-retardant properties of the cured epoxy resins were improved by the incorporation of both silicone and phosphorus moieties. The synergistic effect of silicone and phosphorus enhanced the limiting oxygen index values, which was observed for siliconized epoxy resins cured with phosphorus containing diamine compound.     

Studies on the curing kinetics of epoxy resins using silicon containing amide-amines

Curing kinetics of diglycidyl ether of bisphenol-A (DGEBA) in the presence of novel silicon containing amide-amines were investigated by the dynamic differential scanning calorimetry. Silicon containing amide-amines were prepared by reacting 2.5 moles of 4,4'-diaminodiphenyl ether (E)/4,4'-diaminodiphenyl methane (M)/3,3'-diaminodiphenyl sulfone (mS)/bis(m-aminophenyl) methyl phosphine oxide (B) with one mole of bis(4-chlorobenzoyl) dimethyl silane. The multiple heating rate method (5, 10, 15 and 20°C min^-1) was used to study the curing kinetics of epoxy resins in the presence of stoichiometric amounts of amide-amines having molecular masses in the range of 660 to 760 g mol^-1. The peak exotherm temperature depends on the heating rate as well as on the structure of amide-amines. Activation energy of curing reaction as determined in accordance to the Ozawa's method was found to be dependent on the structure of amine. The thermal stability of the isothermally cured resins was also evaluated using dynamic thermogravimetry in a nitrogen atmosphere. The char yield was the highest in case of resins cured with amide-amines having both phosphorus and silicon atoms. This revised version was published online in July 2006 with corrections to the Cover Date.     

Quantification of anhydride groups in anhydride‐based epoxy hardeners by reaction headspace gas chromatography

We demonstrate a reaction headspace gas chromatographic method for quantifying anhydride groups in anhydride‐based epoxy hardeners. In this method, the conversion process of anhydride groups can be realized by two steps. In the first step, anhydride groups in anhydride‐based epoxy hardeners completely reacted with water to form carboxyl groups. In the second step, the carboxyl groups reacted with sodium bicarbonate solution in a closed sample vial. After the complete reaction between the carboxyl groups and sodium bicarbonate, the CO₂ formed from this reaction was then measured by headspace gas chromatography. The data showed that the reaction in the closed headspace vial can be completed in 15 min at 55°C, the relative standard deviation of the reaction headspace gas chromatography method in the precision test was less than 3.94%, the relative differences between the new method and a reference method were no more than 9.38%. The present reaction method is automated, efficient and can be a reliable tool for quantifying the anhydride groups in anhydride‐based epoxy hardeners and related research.     

Liquid crystalline thermosets from dimeric LC epoxy resins cured with primary and tertiary amines

Liquid crystalline thermosets (LCTs) were prepared by curing difunctional LC dimeric epoxy monomers with imine moieties in the mesogenic core and central spacers of different length. Primary diamines or tertiary amines were used as curing agents obtaining materials with different characteristics. The results obtained were related to the mesogen structure, since dipolar moments in the mesogenic cores affect the ability to form ordered networks.     

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.     

Curing behavior and toughening performance of epoxy resins containing hyperbranched polyester

The effects of the hyperbranched polyester with hydroxyl end groups (HBPE‐OH) on the curing behavior and toughening performance of a commercial epoxy resin (diglycidyl ether of bisphenol A, DGEBA) were presented. The addition of HBPE‐OH into DGEBA strongly increased its curing rate and conversion of epoxide group due to the catalytic effect of hydroxyl groups in HBPE‐OH and the low viscosity of the blend at curing temperature. The improvements on impact strength and critical stress intensity factor (or fracture toughness, K_1c) were observed with adding HBPE‐OH. The impact strength was 8.04 kJ m^?1 when HBPE‐OH reached 15 wt% and the K_1c value was approximately two times the value of pure epoxy resin when HBPE‐OH content was 20 wt%. The morphology of the blends was also investigated, which indicated that HBPE‐OH particles, as a second phase in the epoxy matrix, combined with each other as the concentration of HBPE‐OH increased. Copyright © 2004 John Wiley & Sons, Ltd.     

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.     

Syntheses and characterizations of thermally reworkable epoxy resins. Part I

To meet the need for reworkable epoxy resins, a series of cycloaliphatic diepoxides containing thermally cleavable carbamate linkages were synthesized and characterized. These materials were shown to undergo curing reactions with cyclic anhydride in a similar fashion as a commercial cycloaliphatic epoxide, except that the carbamate group within the diepoxides can act as the internal catalyst. Furthermore, cured samples of the formulations from these diepoxides started to decompose at lower temperatures, i.e., between 200–300°C as compared with 350°C for the cured sample of the commercial cycloaliphatic epoxide, which showed their potential to be used as reworkable underfill encapsulants in the electronic packaging area. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2991–3001, 1999     

New generation of fire retardant polyester resins

Smoke evolution [in a smoke chamber (750 x 750 x 1000) ± 5 mm, Polish Standard PN-91/K-02501 equivalent to UIC 561-OR (1991)] was studied in, and the oxygen index flammability test (Polish Standard PN-76/C-89020) was carried out for, glass-reinforced polyester (GRP) laminates obtained with unsaturated polyester (UP) resins containing chlorine and bromine in the chain. In these studies, the effect on these properties of such additives as ZnSnO₃ (ZS), ZnSn(OH)₆ (ZHS), Al(OH)₃ or Mg(OH)₂ and Sb₂O₃ in an amount of up to 30 mass-% was determined. The most efficient ignition and smoke-evolution retarder from among the investigated compounds was ZS and ZHS, whereas an essential reduction in smoke evolution was observed also with Sb₂O₃. GRP laminates with these additives meet the fire-safety recommendations concerning smoke evolution from materials used in transportation means and in the building industry.     

Evaluation of solubility parameters during polymerisation of amine‐cured epoxy resins

A new procedure for the calculation of solubility parameter evolution during polymerisation has been developed for amine‐cured epoxy systems, which allows quantitative thermodynamic modelling of chemically induced phase separation (CIPS). Solubility parameters calculation, chemical analysis based on near infrared spectroscopy and curing kinetics results obtained by differential scanning calorimetry will allow to model the evolution of the Flory–Huggins interaction parameter in amine‐cured epoxy blends. The resin system investigated was based on a diglycidyl ether bisphenol A (DGEBA) epoxy resin cured with isophorone diamine (IPD) blended with various reactive epoxydised dendritic hyperbranched polymer modifiers (HBP), yielding a CIPS‐controlled morphology. The analysis showed the evolution of the different contributions to the solubility parameters to follow the polymerisation kinetics. The dispersive contribution had the highest value at all stages of polymerisation, but the hydrogen and polar contributions showed the largest variation. By evaluating the dynamic evolution of the solubility parameter components, the Flory–Huggins interaction parameter in the epoxy resin‐hyperbranched polymer blends has been modelled as a function of time. This procedure, combined with thermodynamic modelling, will enable to predict phase diagrams in CIPS thermosetting blends quantitatively. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 1883–1892, 2000     

Physical aging studies in epoxy resins. I. Kinetics of the enthalpy relaxation process in a fully cured epoxy resin

The physical aging of an epoxy resin based on diglycidyl ether of bisphenol-A cured by a hardener derived from phthalic anhydride has been studied by differential scanning calorimetry. The isothermal curing of the epoxy resin was carried out in one step at 130°C for 8 h, obtaining a fully cured resin whose glass transition was at 98.9°C. Samples were aged at temperatures between 50 and 100°C for periods of time from 15 min to a maximum of 1680 h. The extent of physical aging has been measured by the area of the endothermic peak which appears below and within the glass transition region. The enthalpy relaxation was found to increase gradually with aging time to a limiting value where structural equilibrium is reached. However, this structural equilibrium was reached experimentally only at an aging temperature of T_g-10°C. The kinetics of enthalpy relaxation was analysed in terms of the effective relaxation time τ_eff. The rate of relaxation of the system given by 1/τ_eff decreases as the system approaches equilibrium, as the enthalpy relaxation tends to its limiting value. Single phenomenological approaches were applied to enthalpy relaxation data. Assuming a separate dependence of temperature and structure on τ, three characteristic parameters of the enthalpic relaxation process were obtained (In A = ?333, E_H = 1020 kJ/mol, C = 2.1 g/J). Comparisons with experimental data show some discrepancies at aging temperatures of 50 and 60°C, where sub-T_g peaks appears. These discrepancies probably arise from the fact that the model assumes a single relaxation time. A better fit to aging data was obtained when a Williams-Watts function was applied. The values of the nonexponential parameter β were slightly dependent on temperature, and the characteristic time was found to decrease with temperature. © 1994 John Wiley & Sons, Inc.