Study on intumescent flame retarded polystyrene composites with improved flame retardancy

The flame retardancy and thermal stability of ammonium polyphosphate/tripentaerythritol (APP/TPE) intumescent flame retarded polystyrene composites (PS/IFR) combined with organically-modified layered inorganic materials (montmorillonite clay and zirconium phosphate), nanofiber (multiwall carbon nanotubs), nanoparticle (Fe₂O₃) and nickel catalyst were evaluated by cone calorimetry, microscale combustion calorimetry (MCC) and thermogravimetric analysis (TGA). Cone calorimetry revealed that a small substitution of IFR by most of these fillers (≤2%) imparted substantial improvement in flammability performance. The montmorillonite clay exhibited the highest efficiency in reducing the peak heat release rate of PS/IFR composite, while zirconium phosphate modified with C₂₁H₂₆NClO₃S exhibited a negative effect. The yield and thermal stability of the char obtained from TGA correlated well with the reduction in the peak heat release rate in the cone calorimeter. Since intumesence is a condensed-phase flame process, the MCC results showed features different from those obtained from the cone calorimeter.     

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.     

Thermal and Mechanical Properties of Zeolite Filled Ethylene Vinyl Acetate Composites

Ethylene vinyl acetate (EVA) composites filled with zeolite (25 vol.%) were prepared using an internal mixer followed by compression molding machine. In order to enhance the thermal properties and fire retardancy of the composites, an intumescent flame retardant consisting of ammonium polyphosphate (APP)/pentaerythritol (PER) was incorporated into the composites. Two kinds of flame retardants were used which are untreated APP (APP1) and silane treated APP (APP2), where their effectiveness was evaluated by means of differential scanning calorimetry (DSC) and also thermogravimetric analysis (TGA). The results showed that both types of flame retardants have the ability to enhance the thermal stability of EVA/zeolite composites by producing charred layer which protects the underlying composites from the action of flame. Moreover, the incorporation of APP1 and APP2 has a significant effect on the composites degree of crystallinity. Meanwhile the results of tensile testing showed that the composites with APP2/PER exhibit better tensile properties compared to that with APP1/PER. This is expected since the application of silane-treated APP (APP2) could improve the dispersion of APP particles within EVA matrix.     

Probing synergism, antagonism, and additive effects in poly(vinyl ester) (PVE) composites with fire retardants

Potential fire retardants, including copper hydroxy dodecyl sulfate (CHDS), organically-modified montmorillonite (Cloisite 15A), and resorcinol di-phosphate (RDP), were added to pure poly(vinyl ester) (PVE) individually or in combinations at low concentration formulations. Thermogravimetric analysis and cone calorimetry were used to study the thermal stability and fire performance of the composites. Synergistic, antagonistic, and additive effects were observed depending on the specific formulation. Time to self-sustained combustion is greatly reduced, but the flame extinguishes faster, for the composites containing CHDS alone or in combination with either RDP or Cloisite 15A compared to the virgin polymer. The presence of copper in PVE composites containing additive, CHDS, may be responsible for the enhanced thermal stability and fire performance.     

Synergistic effect between a novel hyperbranched charring agent and ammonium polyphosphate on the flame retardant and anti-dripping properties of polylactide

A novel hyperbranched polyamine charring agent (HPCA), a derivative of triazines, was synthesized and well characterized by ¹H NMR and FTIR. HPCA and ammonium polyphosphate (APP) were added into polylactide (PLA) resin as an intumescent flame retardant (IFR) system to impart flame retardancy and dripping resistance to PLA. The flammability and thermal stability of IFR-PLA composites were investigated by limiting oxygen index (LOI), UL-94 vertical burning, cone calorimetry and thermogravometric analysis (TGA) tests. The results showed that the IFR system had both excellent flame retardant and anti-dripping abilities for PLA. The TGA curves suggested that HPCA has good ability of char formation and when combined with APP, would induce synergistic effect which could be clearly observed. This effect greatly promoted the char formation of IFR-PLA composites, hence improved the flame retardant property. Additionally, the structure and morphology of char residues were studied by XPS, FTIR and SEM.     

Comparative study on the flammability of polyethylene modified with commercial fire retardants and a zinc aluminum oleate layered double hydroxide

Polyethylene (PE) was modified by the addition of a layered double hydroxide of zinc aluminum oleate (ZnAl) and/or commercial fire retardants. Commercial additives included: melamine polyphosphate (MPP), ammonium polyphosphate (APP), triphenol phosphate (TPP), resorcinol diphosphate (RDP), decabromophenyl oxide (DECA) and antimony oxide (AO). The thermal stability and the combustion behaviors of the new composite polymeric materials are evaluated in TGA experiments and cone calorimetry. At 20% total additive loading, APP and LDH enhance the thermal stability of the PE composites and favor char formation. ZnAl leads to the best reduction in the peak of heat release rate (PHRR), 72%, while the combinations of PE with other additives give reductions in the range 20-40%. The combination of DECA and AO effectively increases the time to ignition and time to PHRR while LDH lowers these two parameters. APP and MPP on the other hand, do not affect the time to ignition, but they effectively increase the time to PHRR relative to the pristine polymer.     

Microencapsulation of bisphenol-A bis (diphenyl phosphate) and influence of particle loading on thermal and fire properties of polypropylene and polyethylene terephtalate

Microencapsulated flame retardant, bisphenol-A bis (diphenyl phosphate) (BDP), with a silane shell was prepared by sol–gel process with the goal of incorporating them in polymeric matrices by melt blending to improve the flame retardancy of isotactic polypropylene (iPP) and polyethylene terephtalate (PET). The influence of the loading content on thermal transitions has been studied by differential scanning calorimetry (DSC), the thermal stability of the polymer/microcapsules composites has been assessed by thermogravimetric analysis (TGA) and cone calorimetry has been used to study the fire reaction. It was noticed that the microcapsules have a limited influence on the thermal transitions of iPP matrix, but a decrease of the melting and glass transition temperatures was detected for the PET microcomposites. TGA results showed that the addition of microcapsules could improve char formation of the PET systems both in nitrogen and in air atmospheres, whereas only a small improvement of the thermal stability was detected in oxidative atmosphere for the iPP samples. Furthermore, cone calorimeter experiments show that the incorporation of microcapsules in the iPP gives almost no improvement in the iPP fire reaction. However, the microcapsules act as flame retardant in PET reducing the heat release rate during the combustion and the total heat evolved. Therefore, microcapsules can act as a char promoter agent to enhance the fire resistance in the case of PET.     

The effects of several sulfonates on thermal and fire retardant properties of poly(methyl methacrylate) and polystyrene

Three different sulfonates (sodium diphenylamine‐4‐sulfonate [SDPAS], 3‐(1‐pyridino)‐1‐propane sulfonate [PPS], and ammonium sulfamate) have been melt blended with polystyrene (PS) or poly(methyl methacrylate) (PMMA) and with clay to make composites. All have been examined by X‐ray diffraction to determine the morphology, by thermogravimetry to determine thermal stabilities, and by cone calorimetry to evaluate fire retardancy. All three sulfonates enhance the thermal stability of the PMMA composites, and SDPAS achieves the greatest improvement. SDPAS also seems to aid in the dispersion of the clay in the polymer. Combination of sulfonates (5 or 10 wt% SDPAS, or 5 wt% PPS) with an organically modified clay exhibit enhanced fire retardancy. The three sulfonates did not enhance the thermal stability of the PS composites; however, there is a reduction in the peak heat release rate. The presence of ammonium sulfamate in PS brings about a 52% reduction in the peak heat release rate. The combination of sulfonates (5 or 10 wt% PPS, or 10 wt% SDPAS) with an organically modified clay provides some fire retardancy to the PS composites. Copyright © 2013 John Wiley & Sons, Ltd.     

The effects of irradiation cross-linking on the thermal degradation and flame-retardant properties of the HDPE/EVA/magnesium hydroxide composites

High-density polyethylene/ethylene vinyl-acetate copolymer/magnesium hydroxide composites were crosslinked via high-energy electron beam irradiation in the presence of triallylisocyanurate. The structure of the cross-linking network was determined with the help of rheological measurements through advanced rheological extended systems (ARES). The thermal and flame-retardant properties of the irradiated composites were investigated by thermogravimetric analysis (TGA), differential scanning calorimetry (DSC) and cone calorimetry. Results showed that the cross-linking network structure could enhance the thermal stability of composites, and did favor to smoke suppression. However, the peak heat release rate (PHRR) increased and the time to PHRR shortened, inferring that the composites after irradiation cross-linking were easier to combust. The char microstructure after cone calorimetry test was observed and used to give explanation of the above results.     

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.     

Synergistic effect between expandable graphite and ammonium polyphosphate on flame retarded polylactide

Synergistic effect was observed between expandable graphite (EG) and ammonium polyphosphate (APP) on flame retarded polylactide (PLA) in this paper using limiting oxygen index (LOI), thermal gravimetric analysis (TGA), scanning electron microscopy (SEM) and X-ray spectroscopy (XPS) and cone calorimeter tests etc. In the experiments, PLA composites with 15 wt% of APP/EG(1:3) combinations showed a LOI value of 36.5 and V-0 rating in UL-94 tests, greatly improved flame retardant properties from composites with APP or EG alone. Results from TGA and cone calorimeter demonstrated that APP/EG combination could retard the degradation of polymeric materials above the temperature of 520 °C by promoting the formation of a compact char layer. This char layer protects the matrix effectively from heat penetrating inside and prevents its further degradation, resulting in lower weight loss rate and better flame retarded performance.     

Fire properties of silylated α‐zirconium phosphate composites based on polystyrene

α‐zirconium phosphate (ZrP) (prepared by both reflux and hydrothermal methods) is silylated with chlorotrimethylsilane and characterized by X‐ray diffraction, Fourier transform infrared spectroscopy and scanning electron microscopy. Polystyrene/silylated‐ZrP composites show higher thermal stability as the ZrP content increases. Cone calorimetry suggests that the reduction of the peak heat release rate of polystyrene (PS)/ZrP composites does not increase as the ZrP loading increases; the aspect ratio of ZrP has little effect in fire performance of PS/ZrP composites. Copyright © 2013 John Wiley & Sons, Ltd.     

Efficiency of wollastonite and ammonium polyphosphate combinations on flame retardancy of polystyrene

The thermal and fire properties of polystyrene (PS) flame retarded by a system composed of ammonium polyphosphate (APP) and wollastonite (W) were investigated by thermogravimetric analysis, pyrolysis‐combustion flow calorimeter, pyrolysis gas chromatography mass spectrometry, cone calorimetry and epiradiator. The combustion residues were observed by scanning electron microscopy/energy dispersive X‐ray spectroscopy and analyzed by X‐ray diffraction. The combination of both additives enables increasing the thermal stability of PS while increasing simultaneously the high temperature residue. The peak of HRR was also significantly reduced while time to ignition varied depending on the composition. It was shown that the degradation pathway of PS was affected by the presence of the additives implying a reduction of the effective heat of combustion. In the condensed phase, APP decomposition promotes char formation and favors the reactivity between phosphorus and silicate. A layer composed of char, W and a mixture of calcium and silicon phosphate is formed at the sample surface during combustion. This layer is cohesive enough to limit the release of combustible gases to the gas phase. Moreover, the thermally stable protective layer reaches high temperature enabling the re‐irradiation of a part of the incident heat flux. The flame retardancy of PS is thus enhanced. Copyright © 2012 John Wiley & Sons, Ltd.     

Fire retarded polyurethane foam composites based on steel slag/ammonium polyphosphate system: A novel strategy for utilization of metallurgical solid waste

A series of FR-RPUF composites were prepared by a one-step water foaming process with ammonium polyphosphate (APP) and steel slag (SS) as flame retardants. Thermogravimetric analysis (TG), limiting oxygen index (LOI), UL-94 vertical combustion test, microscale combustion calorimetry (MCC), TG-Fourier transform infrared spectrometry (TG-FTIR), scanning electron microscopy (SEM), Raman spectra and FTIR were used to investigate the thermal stability, flame retardancy, combustion performance, gas phase products, and char residue morphology of FR-RPUF composites. TG test results showed that the initial decomposition temperature (T_-5wt%) and char residue rate at 700°C of RPUF/APP/SS composites were significantly enhanced by the addition of APP and SS, and the thermal stability of the composites was improved. Flame retardant test results confirmed the significantly increased LOI values of RPUF/APP/SS composites with V-0 rating. TG-FTIR also confirmed the obviously decreased release of toxic gases and flammable gases in the combustion of RPUF/APP/SS composites. SEM and Raman spectra of char residues for the composites suggested that APP/SS system improved the compactness and graphitization degree of char layer for RPUF/APP/SS composite. The above researches provide a new strategy for the utilization of SS in fire safety engineering.     

The role of the trivalent metal in an LDH: Synthesis, characterization and fire properties of thermally stable PMMA/LDH systems

Two layered double hydroxides (LDHs), calcium aluminum undecenoate (Ca₃Al) and calcium iron undecenoate (Ca₃Fe), have been prepared by the co-precipitation method. XRD analysis of these LDHs reveals that they are layered materials and FT-IR and TGA confirmed the presence of the undecenoate anions in the material produced. The PMMA composites were prepared by bulk polymerization and the samples were characterized by XRD, TEM, TGA and cone calorimetry. Both additives greatly enhance the thermal stability of PMMA, while the calcium aluminum LDH gives better results when the fire properties were examined using the cone calorimeter.     

Does organic modification of layered double hydroxides improve the fire performance of PMMA?

The effect of modified layered double hydroxides (LDHs) on fire properties of poly(methyl methacrylate) is investigated. Organically-modified LDHs were prepared via rehydration of calcined hydrotalcite in a palmitate solution. Composites consisting of the organo-LDHs, unmodified hydrotalcite and calcined oxides were prepared with poly(methyl methacrylate) using melt blending. Thermal and fire properties of the (nano)composites were studied. The thermogravimetric analyses of the composites show an increase in thermal stability. Fire performance, evaluated using cone calorimetry, show that organically-modified LDHs composites give the best reductions in peak heat release rate, PHRR, i.e., 51% at 10% weight loading. Dispersion of the LDHs was characterized using transmission electron microscopy and X-ray diffraction. Nanocomposite formation was observed with organically-modified LDHs, while the unmodified LDH composites gave only microcomposites.     

Preparation of piperazine cyanurate by hydrogen‐bonding self‐assembly reaction and its application in intumescent flame‐retardant polypropylene composites

Piperazine cyanurate (PCA) is designed and synthesized via hydrogen‐bonding self‐assembly reactions between piperazine and cyanuric acid. Chemical structure and morphology of PCA are investigated by Fourier transform infrared spectroscopy and scanning electron microscopy, respectively. The prepared PCA is combined with ammonium polyphosphate (APP) to prepare flame‐retardant polypropylene (PP) composites. Thermostability, flammability, and combustion characteristics of PP composites are analyzed. The maximum thermal decomposition rate of flame‐retarded PP composites has an apparent reduction compared with that of pure PP, and obvious char is left for this intumescent flame retardant (IFR) system of APP and PCA. A high limiting oxygen index value and UL‐94 V‐0 rating are achieved with addition of APP and PCA. In cone calorimetry test, heat and smoke releases of PP are significantly decreased by this IFR system. Gaseous decomposition products during the thermal decomposition of flame‐retardant composites are studied. Chemical structure and morphology of char residues are analyzed. The results illustrate that APP and PCA have a superb synergistic action in the aspect of improvement in fire safety of PP. A possible flame‐retardant mechanism is concluded to reveal the synergism between APP and PCA.     

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.     

A method for simultaneously improving the flame retardancy and toughness of PLA

In order to modify the brittleness and flame retardant properties of poly(lactic acid) (PLA), a series of flame retardant toughened PLA composites were prepared using poly(ethylene glycol) 6000 (PEG6000) as a toughening and charring agent together with ammonium polyphosphate (APP) as an acid source and blowing agent. The fire and thermal behavior of PLA/PEG/APP composites was evaluated by limiting oxygen index (LOI), UL‐94, cone calorimeter, and thermogravimetric analysis (TGA). The results showed that the PLA/PEG/APP system had good charring ability and could improve the flame retardancy of PLA. When the content of APP in the composites was more than 5 wt%, all samples could reach UL‐94 V‐0 rating. The results of mechanical property tests demonstrated that the brittleness of PLA was also improved after blended with PEG6000. All the PLA/PEG/APP composites with an APP content of less than 10 wt% showed an obvious neck and fracture behavior, that is, the tensile behavior of PLA was changed from brittle to ductile. Copyright © 2010 John Wiley & Sons, Ltd.     

Variation of benzyl anions in MgAl-layered double hydroxides: Fire and thermal properties in PMMA

Magnesium aluminum layered double hydroxides (MgAl-LDHs) intercalated with a range of benzyl anions were prepared using the coprecipitation method. The benzyl anions differ in functionality (i.e. carboxylate, sulfonate, and phosphonate) and presence or absence of an amino substituent. Various methods for preparing LDHs (i.e. ion exchange, coprecipitation and rehydration of the calcined LDH methods) have been compared with the MgAl-benzene phosphonate and their effect on fire and thermal properties was studied. After characterization, the MgAl-LDHs were melt-blended with poly(methyl methacrylate) (PMMA) at loadings of 3 and 10% by weight to prepare composites. Characterization of the LDHs and the PMMA composites was performed using FTIR, XRD, TGA, transmission electron microscopy (TEM) and cone calorimetry. FTIR and XRD analyses confirmed the presence of the charge balancing benzyl anions in the galleries of the MgAl-LDHs. Improvements in fire and thermal properties of the PMMA composites were observed. The cone calorimeter revealed that the addition of 10% MgAl-LDHs reduces the peak heat release rate by more than 30%.