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.     

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

The flame retardant mechanism of a newly synthesized phosphorus-containing reactive amine, which can be used both as crosslinking agent in epoxy resins and as flame retardant, was investigated. The mode of action and degradation pathway were investigated by in situ analysis of the gases evolved during the degradation by thermogravimetric measurements coupled online with infrared (TG-EGA-FTIR) and mass spectroscopy (TG/DTA-EGA-MS) and by solid residue analysis by infrared (ATR) spectroscopic methods and X-ray photoelectron spectroscopy (XPS). It was observed that the main difference in the degradation of the reference and the flame retardant system is that the degradation of the latter begins at lower temperature mainly with the emission of degradation products of the phosphorus amine, which act as flame retardants in the gas phase slowing down the further degradation steps. At the high temperature degradation stage the solid phase effect of the phosphorus prevails: the formation of phosphorocarbonaceous intumescent char results in a mass residue of 23.4%. The ratio of phosphorus acting in gas phase and solid phase, respectively, was determined on the basis of thermogravimetric and XPS measurements.     

Influence of oxidation state of phosphorus on the thermal and flammability of polyurea and epoxy resin

The focus of this study is an investigation of the effect of oxidation state of phosphorus in phosphorus-based flame retardants on the thermal and flame retardant properties of polyurea and epoxy resin. Three different oxidation states of phosphorus (phosphite, phosphate and phosphine oxide) additives, with different thermal stabilities at a constant phosphorus content (1.5 wt.%) have been utilized. Thermal and flame retardant properties were studied by TGA and cone calorimetry, respectively. The thermal stability of both polymers decreases upon the incorporation of phosphorus flame retardants irrespective of oxidation state and a greater amount of residue was observed in the case of phosphite. Phosphate was found to be better flame retardant in polyurea, whereas phosphite is suitable for epoxy resin. Phosphite will react with epoxy resin by trans-esterification, which is demonstrated by FTIR and ³¹P NMR. Further, TG–FTIR and XPS studies also provide information on flame retardancy of both polymers with phosphorus flame retardants.     

Synthesis of phosphorus-based flame retardant systems and their use in an epoxy resin

Methods are proposed to synthesize efficient organophosphorous compounds and combine them with montmorillonite nanoparticles. The chemical-physical structure and mechanism of action of the new systems were studied in epoxy resin. Best results were achieved using the fully phosphorylated calixresorcinarene derivative: the heat release rate peak could be decreased by 61% and the LOI value was increased from 21 to 28. The salt form of additives in case of phosphorylated phloroglucine derivatives was not advantageous in epoxy resin, because the additives could not participate in the crosslinking process effectively due to their inhomogenous distribution in the matrix. The incorporation of the nanoparticles did not create the desired flame retardant effect which can be explained by the increased heat conductivity and lower mobility of the nanoparticles due to the crosslinked structure.     

Novel DOPO-based flame retardants in high-performance carbon fibre epoxy composites for aviation

Two novel, halogen-free, phosphorus-based oligomeric flame retardants are investigated in the commercial epoxy resin RTM6 and ∼70 wt.% carbon fibre RTM6 composites (RTM6-CF) with respect to pyrolysis and fire behaviour. The flame retardants are based on 9,10-dihydro-9-oxy-10-phosphaphenanthrene-10-oxide (DOPO) units linked to the star-shaped aliphatic ground body tetra-[(acryloyloxy)ethyl] pentarythrit (DOPP), or heterocyclic tris-[(acryloyloxy)ethyl] isocyanurate (DOPI), respectively. The glass transition temperature is reduced by adding DOPP and DOPI, but the mechanical properties of the composites (e.g. interlaminar shear strength (ILSS) and G_c in mode I and II) remain unchanged. Decomposition models are proposed based on mass loss, evolved gas analysis (TG–FTIR) and condensed product analysis (hot stage cell within FTIR). The fire behaviour is investigated comprehensively (UL 94, limiting oxygen index (LOI) and cone calorimeter). Both flame retardants act in the gas phase through flame inhibition and in the condensed phase through charring. The UL 94 of RTM6 is improved from HB to V-1 and V-0; the LOI from 25% to 34–38%. Peak heat release rate (PHRR) and total heat evolved (THE) are lowered by 31-49% and 40–44%, respectively. Adding CF increases the residue, reduces the THE, but suppresses the charring due to RTM6 and flame retardants. Thus the THE of RTM6-CF is reduced by about 25% when DOPI and DOPP are added. However, UL 94: V-0 and LOI of 45% and 48% are achieved with ∼0.6 wt.% phosphorus.     

Mechanical properties of polymer composites based on commercial epoxy vinyl ester resin and glass fiber

The effect of the addition of methyl ethyl ketone peroxide (MEKP) and cobalt naphthenate (CoNaph) on the mechanical behavior of epoxy vinyl ester resin (EVER) laminates has been investigated by using a factorial experimental design, in which the MEKP and NaphCo contents were varied. Previous results showed that there is an interaction effect between the process variables analysed on the mechanical properties evaluated. It was also observed that the MEKP/CoNaph ratio affected the tensile behavior of the EVER/glass fiber composites.     

石墨烯改性树脂基复合材料力学性能研究进展

树脂基复合材料具有比强度高、比模量大、耐高温、耐腐蚀、质轻等诸多优点,在航天军工、生物医疗、电子封装、体育器材等众多领域得到广泛应用。石墨烯作为一种典型的二维纳米材料,凭借其独特结构以及优异的物理化学性能而备受关注。近年来的研究表明石墨烯可以通过对增强纤维改性和对基体树脂改性的方法来提高树脂基复合材料的力学性能。本文介绍了石墨烯改性树脂基复合材料的增强增韧机理,对石墨烯改性纤维(碳纤维、玻璃纤维、芳纶纤维)增强复合材料以及树脂的改性方法进行了综述;着重阐述了石墨烯改性树脂基复合材料力学性能的研究进展,分析了石墨烯改性树脂基复合材料研究中依旧存在的两大问题,即石墨烯的分散性和界面结合问题,并对石墨烯改性树脂基复合材料的未来发展前景进行了展望。     

Soft ionisation analysis of evolved gas for oxidative decomposition of an epoxy resin/carbon fibre composite

Soft ionisation mass spectrometry was used to investigate the oxidative decomposition of an epoxy resin/carbon fibre composite using thermogravimetry (TG) coupled with mass spectrometry (MS). Through comparison between decomposition in air and in argon, it was recognized that the first step of the oxidative decomposition of the epoxy resins was similar to the decomposition in argon. During the devolatilisation process, the oxidative decomposition underwent a thermal decomposition leading to the formation of a large amount of volatile products which were subsequently oxidized into water and carbon dioxide. The gas produced in the thermal decomposition was not oxidized completely leaving some organic volatiles in the emissions. Using soft ionisation, the components of the evolved gases were identified by mass spectrometry.     

Chemical recycling of carbon fibre reinforced epoxy resin composites in subcritical water: Synergistic effect of phenol and KOH on the decomposition efficiency

The combination of phenol and potassium hydroxide (KOH) was used to chemically recycle carbon fibre reinforced epoxy resin cured with 4,4′-diaminodiphenylmethane in subcritical water. This combination had a synergistic effect on decomposing this kind of epoxy resin. The main decomposition products from the epoxy resin were identified by means of GC-MS, and a possible free-radical reaction mechanism for the decomposition of epoxy resin is proposed. The recovered carbon fibres were characterized using single fibre tensile tests, scanning electron microscopy and X-ray photoelectron spectroscopy. Compared to virgin carbon fibres after sizing removal, the surface compositions of the recovered carbon fibres had little change and the tensile strength of the recovered carbon fibres was well retained.     

An improved microbond test method for determination of the interfacial shear strength between carbon fibers and epoxy resin

An improved microbond method, with a corresponding testing device, was developed to measure the interfacial shear strength (IFSS) between carbon fibers and epoxy resin. Compared to other methods, this proposed approach is both highly efficient and easy to operate. As a case study for this new method, we measured the IFSS between carbon fibers and epoxy resin. Although the average IFSS obtained was only 7.08 MPa, which is much lower than values documented in several previous studies, the displacement-load curves demonstrate the strong reliability of this method. The lower IFSS could be explained by the highly inert surface of the carbon fibers, which was highly graphitized and had no sizing treatment. Therefore, this method has high potential in applications for screening the sizing agents of carbon fibers or optimizing the surface sizing processes.     

Thermomechanical behaviors and dielectric properties of polyaniline‐doped para‐toluene sulfonic acid/epoxy resin composites

Composites based on conductive organic/inorganic fillers dispersed in insulating matrix have been widely investigated because of their widespread applications such as electromagnetic shielding, electrostatic discharge, and sensors. In this context, novel composite materials based on epoxy resin matrix charged with polyaniline (PANI)‐doped para‐toluene sulfonic acid were elaborated. Fourier transform infrared spectroscopy, X‐ray diffraction and scanning electron microscopy were used to check the structure and the morphology of the samples. Viscoelastic behavior and thermal stability of the composites were explored by dynamic mechanical thermal analysis and thermogravimetric analysis. It was shown that the PANI particles exhibited a partial crystalline structure and were homogeneously dispersed in epoxy matrix. Consequently, this structure affected the thermal stability and viscoelastic properties of the composites. Furthermore, the dielectric and electrical properties were investigated up to 1 MHz. Measurements of dielectric properties revealed that with loading fillers in matrix, the dielectric parameters increased to high values at low frequency then decreased at values around 40 and 32 of real and imaginary parts, respectively, at 1 MHz with 15% of PANI content. Copyright © 2011 John Wiley & Sons, Ltd.     

The chemical and dielectric properties of epoxy/(Ba0.8Sr0.2)(Ti0.9Zr0.1)O3 composites for embedded capacitor application

The characteristics of epoxy/(Ba_0.8Sr_0.2)(Ti_0.9Zr_0.1)O₃ (BSTZ) composites are investigated for the further application in embedded capacitor device. The effects of BSTZ ceramic powder filler ratio on the chemical, physical and dielectric properties of epoxy/BSTZ composites are studied. Differential scanning calorimeter (DSC) thermal analysis is conducted to determine the optimum values of hardener agent, curing temperature, reaction heat, and glass transition temperature (T_g). The hardener reaction process starts at about 115 °C and completes at about 200 °C, for that it is appropriate to process of epoxy/BSTZ composites in the range of temperature. The highest glass transition temperature (T_g) of 155 °C is obtained at one equivalent weight ratio (hardener/epoxy). Only the BSTZ phase can be detected in the XRD patterns of epoxy/BSTZ composites. The more BSTZ ceramic powder is mixed with epoxy, the higher crystalline intensity of tetragonal BSTZ phase are revealed in the XRD patterns. The dielectric constant measured at 1 MHz increases from 5.8 to 23.6 as the content of BSTZ ceramic powder in the epoxy/BSTZ composites increases from 10 to 70 wt%. The loss tangents of the epoxy/BSTZ composites slightly increase with the increase of measurement frequency.