Intrinsically flame retardant epoxy resin - Fire performance and background - Part I

The flame retardant effect of newly synthesized phosphorus-containing reactive amine, which can be used both as crosslinking agent in epoxy resins and as a flame retardant, was investigated. The effect of montmorillonite and sepiolite additives on the fire induced degradation was compared to pristine epoxy resin. The effect of combining the organophosphorous amine with clay minerals was also studied. It could be concluded that the synthesized phosphorus-containing amine, TEDAP can substitute the traditional epoxy resin curing agents providing additionally excellent flame retardancy: the epoxy resins flame retarded this way reach 960 °C GWFI value, 33 LOI value and V-0 UL-94 rating - compared to the 550 °C GWFI value, 21 LOI value and “no rate” UL-94 classification of the reference epoxy resin. The peak of heat release was reduced to 1/10 compared to non-flame retarded resin, furthermore a shift in time was observed, which increases the time to escape in case of fire. The flame retardant performance can be further improved by incorporating clay additives: the LOI and the HRR results showed that the optimum of flame retardant effect of clay additives is around 1 mass% filler level in AH-16-TEDAP system. Applying a complex method for mechanical and structural characterization of the intumescent char it was determined that the flame retarded system forms significantly more and stronger char of better uniformity with smaller average bubble size. Incorporation of clay additives (owing to their bubble nucleating activity) results in further decrease in average bubble diameter.     

Preparation of flame retardant polyamide 6 composite with melamine cyanurate nanoparticles in situ formed in extrusion process

This paper is focused on in situ preparation of melamine cyanurate (MCA) nanoparticles from reaction of melamine (MEL) and cyanuric acid (CA) and their flame retardant polyamide 6 (PA6) composite in the extrusion process through a novel reactive processing method. Fourier transform infrared (FT-IR), X-ray diffraction (XRD), differential scanning calorimetry (DSC), thermogravimetric analysis (TGA) and scanning electron microscopy (SEM) were utilized to characterize the in situ formed MCA nanoparticles and their blends with PA6. Introduction of pentaerythritol (LTP) and water-bound plasticizer dioctyl phthalate (DPT) into the extrusion reaction system greatly inhibits the evaporation of water required for melamine and cyanuric acid reaction at high temperature (higher than 180 °C), laying a foundation for successful in situ preparation of MCA through reactive processing. XRD and FT-IR measurements indicate that under the effect of pentaerythritol, dioctyl phthalate and water, melamine really reacts with cyanuric acid to in situ form MCA in extrusion process. The reaction degree is close to 100%. A very important finding through SEM is that the in situ formed MCA particles, which were found to have aspect ratio of about 7.5, radial size in the range of 70-300 nm (mostly 70-90 nm) and crystallite size of less than 22 nm, are uniformly dispersed in the matrix PA6 at nanoscale. The in situ formed MCA nanoparticles greatly improve the flame retardancy and the mechanical properties of flame-retarded PA6 materials, and the introduced plasticizer dioctyl phthalate also ameliorates the related impact property. The obtained flame-retarded PA6 materials have good comprehensive performance with flame retardancy UL-94 V-0 rating at 1.6 and 3.2 mm thickness, tensile strength 48.0 MPa, elongation at break 106.3% and Izod notched impact strength 8.92 kJ/m². Compared with flame-retarded PA6 material with in situ formed MCA, the one prepared through conventional blending of PA6 with commercial MCA product has improved tensile strength but deteriorated impact strength and flame retardancy.     

Preparation, properties and characterizations of halogen-free nitrogen-phosphorous flame-retarded glass fiber reinforced polyamide 6 composite

Halogen free nitrogen-phosphorous flame retardants (PMOP) were prepared through reaction of melamine and polyphosphoric acid in the presence of flame retardant modifier CM with silicotungistic acid as a catalyst in aqueous solution. FT-IR, XRD, DSC and TGA techniques were used to characterize the reaction product PMOP. The obtained flame retardants were then used to prepare flame retardant (FR) polyamide 6 (PA6) composite reinforced with glass fiber (GF) and the factors affecting the flame retardancy of the material were also investigated. The FR GF reinforced PA6 composite and the obtained charred layers were analyzed by utilizing TGA, SEM, FT-IR and XRD. The properties of the charred layer were connected with the flame retardancy of the corresponding material to reveal the flame retarding mechanism of FR GF reinforced PA6 composite. The experimental results show that PMOP flame retardant consists of melamine polyphosphate, melamine phosphate and possible melamine pyrophosphate. The presence of CM was found to improve the flame retardancy of FR GF reinforced PA6 composite. It was experimentally found that PMOP flame retardant, which is comparatively stable in the range of processing temperatures of PA6, is particularly suitable for flame retarding PA6 reinforced with GF. With increasing the flame retardant content, the flame retardancy of the FR reinforced material is not improved so obviously. However, the increase in the GF content greatly improves the flame retardancy of the composite, because GF greatly increases the char yield of material, decreases the maximal thermal decomposition rate, promotes the formation of charred layer with (PNO)_x structure and greatly increases the strength of the charred layer. The prepared FR GF reinforced PA6 composites have good comprehensive properties with flame retardancy 1.6 mm UL 94 V-0 level, tensile strength 76.8 MPa, Young's modulus 11.7 GPa, Izod notched impact strength 4.5 kJ/m², flexural strength 98.0 MPa and flexural modulus 7.2 GPa, showing a better application prospect.     

Glass particles produced by laser ablation for ICP-MS measurements

Pulsed laser ablation (266 nm) was used to generate glass particles from two sets of standard reference materials using femtosecond (150 fs) and nanosecond (4 ns) laser pulses with identical fluences of 50 J cm⁻². Scanning electron microscopy (SEM) images of the collected particles revealed that there are more and larger agglomerations of particles produced by nanosecond laser ablation.In contrast to the earlier findings for metal alloy samples, no correlation between the concentration of major elements and the median particle size was found. When the current data on glass were compared with the metal alloy data, there were clear differences in terms of particle size, crater depth, heat affected zone, and ICP-MS response. For example, glass particles were larger than metal alloy particles, the craters in glass were less deep than craters in metal alloys, and damage to the sample was less pronounced in glass compared to metal alloy samples. The femtosecond laser generated more intense ICP-MS signals compared to nanosecond laser ablation for both types of samples, although glass sample behavior was more similar between ns- and fs-laser ablation than for metal alloys.     

Mechanical and thermal properties and flame retardancy of phosphorus-containing polyhedral oligomeric silsesquioxane (DOPO-POSS)/polycarbonate composites

A novel polyhedral oligomeric silsesquioxane containing 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO-POSS) has been incorporated into polycarbonate (PC) composites in order to study its effect on mechanical and thermal properties and flame retardancy. The mechanical and thermal properties of the DOPO-POSS/PC composites have been investigated by tensile and flexural testing, DSC, and DMA. Slight enhancements of yield stress, and flexural strength and modulus, and obvious decreases of fracture strength and strain of the DOPO-POSS/PC composites were observed with an increase in DOPO-POSS loading. The glass transition temperatures (T_g) of the composites were reduced with increasing DOPO-POSS loading. The morphology of the PC composites was evaluated by SEM, which indicated that the DOPO-POSS was dispersed with a particle size of 100-250 nm in the PC matrix. The thermal degradation behaviour and flame retardancies of PC composites with different DOPO-POSS loadings were investigated by TGA, LOI, UL-94 standard, and cone calorimetry. The composite had an LOI value of 30.5 and a UL-94 rating V-0 when the content of DOPO-POSS was 4%.     

Synthesis and thermal behaviour of polyamide 6/bentonite/ammonium polyphosphate composites

In order to achieve acceptable levels of flame retardancy of polymers, phosphorus-based flame retardant (FR) additives at about 20-30% w/w are required which is too high for conventional synthetic fibres. To know whether more finely sized particles of conventional FRs with or without nanoclay are more effective at the same concentration, composites of PA6 with bentonite and ammonium polyphosphate (APP) have been prepared by melt processing in a twin-screw extruder. XRD peaks and TEM images of PA6/Org-bentonite composite show partially ordered intercalation and ordered exfoliation. Thermal analysis in He shows that thermal stability of PA6 nanocomposite has increased by 18 °C compared with pure PA6 during degradation after 425 °C but it has decreased by 100 °C on inclusion of APP in PA6/nanoclay composites. The char yield is increased by 20% in PA6/bentonite/APP composites. No effect on thermal stability or char yield is observed by reducing the particle size of APP.     

Preparation of polystyrene particles with narrow particle size distribution by γ-ray initiated miniemulsion polymerization stabilized by polymeric surfactant

Co-60 γ-ray initiated miniemulsion polymerization of styrene stabilized by an alkali soluble polymeric surfactant (ASPS) was studied in this work. The affecting factors, including absorbed dose, dose rate, surfactant concentration, and hexadecane (HD) concentration, were systematically studied. The particle size and particle size distribution (PSD) of final latexes was determined by transmission electron microscope (TEM). The results indicated that polystyrene (PS) particles with narrow PSD could be easily prepared by this method, and the particle size could be controlled from 50 nm to 250 nm by adjusting the concentration of HD and ASPS. HD concentration, surfactant concentration, dose rate and total absorbed dose strongly affected the particle size and PSD of PS latexes.     

Effect of a novel charring-foaming agent on flame retardancy and thermal degradation of intumescent flame retardant polypropylene

A new triazine polymer was synthesized by using cyanuric chloride, ethanolamine and ethylenediamine as raw materials. It is used both as a charring agent and as a foaming agent in intumescent flame retardants, designated as charring-foaming agent (CFA). Effect of CFA on flame retardancy, thermal degradation and mechanical properties of intumescent flame retardant polypropylene (PP) system (IFR-PP system) has been investigated. The results demonstrated that the intumescent flame retardant (IFR) consisting of CFA, APP and Zeolite 4A is very effective in flame retardancy of PP. It was found that when the weight ratio of CFA to APP is 1:2, that is, the components of the IFR are 64 wt% APP, 32 wt% CFA and 4 wt% Zeolite 4A, the IFR presents the most effective flame retardancy in PP systems. LOI value of IFR-PP reaches 37.0, when the IFR loading is 25 wt% in PP. It was also found that when the IFR loading is only 18 wt% in PP, the flame retardancy of IFR-PP can still pass V-0 rating, and its LOI value reaches 30.2. TGA data obtained in pure nitrogen demonstrated that CFA has a good ability of char formation itself, and CFA shows a high initial temperature of the thermal degradation. The char residue of CFA can reach 35.7 wt% at 700 °C. APP could effectively promote the char formation of the APP-CFA system. The char residue reaches 39.7 wt% at 700 °C, while it is 19.5% based on calculation. The IFR can change the thermal degradation behaviour of PP, enhance T_max of the decomposition peak of PP, and promote PP to form char, based upon the results of the calculation and the experiment. This is attributed to the fact that endothermic reactions took place in IFR charring process and the char layer formed by IFR prevented heat from transferring into inside of IFR-PP system. TGA results further explained the effective flame retardancy of the IFR containing CFA.     

s-Triazine containing flame retardant hyperbranched polyamines: Synthesis, characterization and properties evaluation

A s-triazine containing hyperbranched polyamine (HBPA) has been synthesized from cyanuric chloride and aromatic diamine, 4,4′-(1,4-phenylenediisopropylidene) bis-aniline by nucleophilic displacement polymerization technique using an A₂ + B₃ approach with high yield (>80%). The synthesized polymer has been characterized by ¹H NMR, ¹³C NMR, FT-IR spectroscopic studies, elemental analysis, solubility and measurement of solution viscosity. The thermogravimetric (TG) analysis and differential scanning calorimetric (DSC) studies indicate that the polymer is thermostable upto 290 °C without any decomposition and has glass transition temperature of 243 °C. The flame retardancy of the pure powder polymer and the blends with linear commercial polymers such as plasticized PVC and LDPE with this hyperbranched polymer were investigated by the measurement of limiting oxygen index (LOI) value. The results show that the polymer has self-extinguishing characteristic (LOI = 38) and acts as an effective flame retardant additive for the above linear base polymers. The synergistic effect of this hyperbranched flame retardant was observed with triphenyl phosphine oxide in the same base polymers. The flammability efficiency of the hyperbranched polyamine is also evaluated by help of thermogravimetric (TG) analysis. The heat aging and leaching in different chemical media did not influence the flame retardancy of the blends.     

Size effect of added LaB6 particles on optical properties of LaB6/Polymer composites

Modified LaB₆ particles with sizes ranging from 50 nm to 400 nm were added into polymethyl methacrylate (PMMA) matrix in order to investigate the effect of added LaB₆ particles on optical properties of LaB₆/PMMA composites. Method of in-situ polymerization was applied to prepare PMMA from raw material—methyl methacrylate (MMA), a process during which LaB₆ particles were dispersed in MMA. Ultraviolet-visible-near infrared (UV-vis-NIR) absorption spectrum was used to study optical properties of the as-prepared materials. The difference in particle size could apparently affect the composites' absorption of visible light around wavelength of 600 nm. Added LaB₆ particles with size of about 70 nm resulted in the best optical properties among these groups of composites.     

Novel flame retardancy effects of DOPO-POSS on epoxy resins

A series of flame retarded epoxy resins (EP) was prepared with a novel polyhedral oligomeric silsesquioxane containing 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO-POSS). The flame retardancy of these EPs was tested by the LOI, UL-94, which indicates that DOPO-POSS has meaningful effects on the flame retardancy of EP composites. 2.5 wt.% DOPO-POSS incorporation into epoxy resin (EP-2.5), results in a LOI value 30.2 and UL-94 V-1 (t₁ = 8 s and t₂ = 3 s) rating. Moreover, self-extinguishing effect through the pyrolytic gases spurt is observed in UL-94 test for the EP-2.5. The pyrolytic gases and thermal stability of epoxy resins with and without DOPO-POSS were detected by TGA-FTIR under air atmosphere. Releases of gaseous species are found to be similar for the pure EP and EP-2.5. The details of fire behaviour, such as TTI, HRR, p-HRR, TSR, SEA, COPR, CO₂PR, and TML, were tested by cone calorimeter. It is notable that 2.5 wt.% DOPO-POSS could make COPR and CO₂PR reach a maximum, which could explain the blowing-out extinguishing effect.     

Size dependence of SiO2 particles enhanced glucose biosensor

A wide size range of SiO₂ particles were synthesized and were used as enzyme immobilization carriers to fabricate glucose biosensors. The size of the particles was in the range of 17-520 nm. These biosensors could be operated under physiological conditions (0.1 M phosphate buffer, pH 7.2). Particle size could affect the performance of SiO₂ modified glucose biosensors drastically. The smaller particles had higher performance. The smallest SiO₂ modified biosensor could work well in the glucose concentration range of 0.02-10 mM with a correlation coefficient of 0.9993. Its sensitivity was 2.08 μA/mM and the detection limit was 1.5 μM glucose.     

Preparation, characterization and enzyme inhibition of methylmethacrylate copolymer nanoparticles with different hydrophilic polymeric chains

Methylmethacrylate copolymer nanoparticles with different hydrophilic chains were prepared by the free radical polymerization of methylmethacrylate with N-isopropylacrylamide (NIPAAm), N-methacrylic acid (MAA), N-trimethylaminoethylmethacrylate chloride (TMAEMC) or N-dimethylaminoethylmethacrylate hydrochloride (DMAEMC). These particles were characterized by particle size and zeta potential. The polymerization conditions were shown to influence the particle size and surface charge. Particle sizes of MMA-NIPAAm nanoparticles after 3 h of reaction reached constant level at 180 nm. An increasing amount of total monomer (0.5-5%) would result in the nanoparticles of particle size of 115-204 nm for 30% NIPAAm of the total monomer. In the same range of 5-40% NIPAAm of the total monomer, the particle size decreased from 280 to 170 nm. The concentration of the initiator APS up to a concentration of 0.2% for MMA-TMAEMC and 0.1% for MMA-NIPAAm showed no effect on the particle size of the final nanoparticle suspensions, while higher concentration would lead to aggregation in the polymerization process. MMA-NIPAAm nanoparticles were pH-dependent in zeta potential at pH 1-12 values reducing from 12.2 mV to −16.8 mV, respectively. Nanoparticles were incubated with pepsin and trypsin at 37 °C for 20 min and their enzyme inhibition was determined. The activity of pepsin decreased to 27% in the presence of MMA-NIPAAm nanoparticles, and MMA-MAA nanoparticles reduced the activity of trypsin to 39%, respectively.     

Synthesis of hydrophobic zinc borate nanoflakes and its effect on flame retardant properties of polyethylene

Zinc borate (2ZnO·3B₂O₃·3.5H₂O) has relatively high dehydration on-set temperature which property permits processing in a wide range of polymer system. But zinc borate particles are hardly dispersed in a polymer matrix so that they prevent their using in industry. To address this problem, we synthesized hydrophobic zinc borate (2ZnO·3B₂O₃·3.5H₂O) nanoflakes by employing solid-liquid reaction of zinc oxide (ZnO) and boric acid (H₃BO₃) in the presence of oleic acid. This method does not bring pollution. By conducting morphological and microscopic analyses, we found that this compound displayed nanoflake morphology with particle size of around 100-200 nm, thickness less than 100 nm and there were uniform mesopores with the diameter about 10 nm within the particles. Furthermore, our products had an effect on flame retardant of polyethylene, especially when the zinc borate was modified by oleic acid.     

The use of multi-channel silicone rubber traps as denuders for polycyclic aromatic hydrocarbons

Atmospheric polycyclic aromatic hydrocarbons are ubiquitous environmental pollutants, which may be present both in the gaseous phase and adsorbed onto the surface of particles. Denuders are sampling devices which have been effectively employed in such partitioning applications. Here we describe and characterise a novel miniature denuder consisting of two multi-channel silicone rubber traps (each 178 mm long, 6 mm o.d. containing 22 silicone tubes), separated by a quartz fibre filter for particle phase collection. The denuder only requires a small portable personal sampling pump to provide sampling flow rates of ∼0.5 L min⁻¹. Theoretical considerations indicated that the air flow through the denuder was expected to be laminar, and the linear velocity arising from longitudinal diffusion was found to be negligible. The calculated particle transmission efficiency through the denuder was found to be essentially 100% for particles > 50 nm, whilst the experimental overall efficiency, as determined by CPC and SMPS measurements, was 92 ± 4%. The size resolved transmission efficiency was <60% for particles below 20 nm and 100% for particles larger than 200 nm. Losses could have been due to diffusion and electrostatic effects. Semi-volatile gaseous analytes are pre-concentrated in the silicone of the trap and may be thermally desorbed using a commercially available desorber, allowing for total transfer and detection of the collected analytes by GC–MS. This enhances detection limits and allows for lower sampling flow rates and shorter sampling times, which are advantageous for studies requiring high temporal resolution.     

Influence of physical properties and chemical composition of sample on formation of aerosol particles generated by nanosecond laser ablation at 213 nm

The influence of sample properties and composition on the size and concentration of aerosol particles generated by nanosecond Nd:YAG laser ablation at 213 nm was investigated for three sets of different materials, each containing five specimens with a similar matrix (Co-cemented carbides with a variable content of W and Co, steel samples with minor differences in elemental content and silica glasses with various colors). The concentration of ablated particles (particle number concentration, PNC) was measured in two size ranges (10–250 nm and 0.25–17 µm) using an optical aerosol spectrometer. The shapes and volumes of the ablation craters were obtained by Scanning Electron Microscopy (SEM) and by an optical profilometer, respectively. Additionally, the structure of the laser-generated particles was studied after their collection on a filter using SEM.     

Statistical design strategies to optimize properties in miniemulsion polymerization of methyl methacrylate

PMMA particles were synthesized by a miniemulsion polymerization method using hexadecane as costabilizer and sodium dodecyl sulfate as surfactant. Full factorial experimental design incorporating the linear regression analysis of the experimental values was used to illustrate the usefulness of this technique in miniemulsion polymerization studies. The effect of initiator concentration, costabilizer concentration, surfactant concentration, sonication time and amplitude, and their interactions on the particle size were identified. Costabilizer and surfactant concentrations influence both particle size individually whereas initiator concentration influences particle size via its interactions with the costabilizer and the surfactant. Sonication parameters influence also greatly the particle size. Two mathematical models were established, and have demonstrated the capability of predicting particle diameter from the synthesis conditions with a precision of 1-2 nm over a range from 75 to 180 nm.     

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

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

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.     

Analytical performance of molecular beacons on surface immobilized gold nanoparticles of varying size and density

The high quenching efficiency of metal nanoparticles has facilitated its use as quenchers in molecular beacons. To optimize this system, a good understanding of the many factors that influence molecular beacon performance is required. In this study, molecular beacon performance was evaluated as a function of gold nanoparticle size and its immobilization characteristics. Gold nanoparticles of 4 nm, 15 nm and 87 nm diameter, were immobilized onto glass slides. Each size regime offered distinctive optical properties for fluorescence quenching of molecular dyes that were conjugated to oligonucleotides that were immobilized to the gold nanoparticles. Rigid double stranded DNA was used as a model to place fluorophores at different distances from the gold nanoparticles. The effect of particle size and also the immobilization density of nanoparticles was evaluated. The 4 nm and 87 nm gold nanoparticles offered the highest sensitivity in terms of the change in fluorescence intensity as a function of distance (3-fold improvement for Cy5). The optical properties of the molecular fluorophore was of significance, with Cy5 offering higher contrast ratios than Cy3 due to the red-shifted emission spectrum relative to the plasmon peak. A high density of gold nanoparticles reduced contrast ratios, indicating preference for a monolayer of immobilized nanoparticles when considering analytical performance. Molecular beacon probes were then used in place of the double stranded oligonucleotides. There was a strong dependence of molecular beacon performance on the length of a linker used for attachment to the nanoparticle surface. The optimal optical performance was obtained with 4 nm gold nanoparticles that were immobilized as monolayers of low density (5.7 × 10¹¹ particles cm⁻²) on glass surfaces. These nanoparticle surfaces offered a 2-fold improvement in analytical performance of the molecular beacons when compared to other nanoparticle sizes investigated. The principles developed in this study would assist in the design of solid phase molecular beacons using gold nanoparticles.