Flammability performance of poly(vinyl alcohol) nanocomposites with zirconium phosphate and layered silicates

Nanocomposites of poly(vinyl alcohol) with α-type zirconium phosphate (PVA/ZrP) and with layered silicates (montmorillonite and hectorite) were prepared by solution blending. Thermal properties and flame retardancy of the materials were characterized by thermogravimetric analysis and microscale combustion calorimetry. PVA/ZrP nanocomposite showed a faster charring process in temperature range between 200 and 350 °C but higher thermal stability and greater char yields above 350 °C and a different heat release rate feature, compared to clay-based samples. Observation of the micrographs of the chars from the nanocomposites present two distinct structures; one constituted by the stacked clay layers on the surface combined with clay-reinforced foams in the interior residue, and the other formed by carbon covered on the tightly curled ZrP nanoplatelets. The results indicated different flame retardant mechanisms of the two nanocomposites, which depend on the chemical/physical effects from the inherent properties of the nanofillers.     

Unsaturated polyester resins modified with phosphorus-containing groups: Effects on thermal properties and flammability

A novel reactive phosphorus-containing monomer [1-oxo-2,6,7-trioxa-1- phosphabicyclo-[2.2.2]octane-methyl diallyl phosphate, PDAP] was synthesized, and various amounts of PDAP were combined with unsaturated polyester by radical bulk polymerization. The resulting flame-retardant unsaturated polyester resin (FR-UPR) samples were investigated by thermogravimetric analysis (TGA), microscale combustion calorimetry (MCC), and limiting oxygen index (LOI) tests. Due to the relatively high phosphorus content of PDAP (18.2 wt%), incorporation of this monomer into unsaturated polyester resin (UPR) led to a marked decrease in the heat release capacity (HRC), the total heat release (THR), an increase in the LOI and the char yield upon combustion. In order to elaborate the interactions between the UPR and PDAP in degradation, differences between the experimental and theoretical mass losses of a FR-UPR sample were evaluated. Furthermore, thermogravimetry-Fourier transform infrared (TG-FTIR) and real-time Fourier transform infrared (RTIR) spectroscopy were employed to investigate the degradation behavior of UPRs, providing insight into the degradation mechanism.     

Thermal and flammability properties of polyethersulfone/halloysite nanocomposites prepared by melt compounding

This paper presents a study of polyethersulfone (PES)/halloysite nanotube (HNTs) nanocomposites prepared by melt compounding either through a simple extrusion process or via a water-assisted extrusion procedure. Scanning and transmission electron microscopy techniques are combined with rheological measurements to assess the influence of polymer end groups (–Cl or –OH) and water injection on the HNTs dispersion state. A morphological transition form microcomposite to nanocomposite is achieved when replacing –Cl chain ends of PES by –OH groups, especially when water is injected during processing. By a combination of Soxhlet extraction and thermogravimetric analysis, we show that some PES(OH) chains are covalently bonded onto the aluminosilicate surface during extrusion. A mechanism describing the physico-chemical action of water is presented. The best system in terms of clay dispersion has been retained to characterize PES-HNTs nanocomposites with respect to their thermo-mechanical, thermal and fire (mass loss calorimetry and UL-94) properties. Dynamic mechanical analysis shows a significant enhancement in the storage modulus of halloysite-based nanocomposites when compared to the unfilled matrix. The improved thermal and thermo-oxidative stability of PES in presence of HNTs is mainly attributed to the labyrinth effect provided by individually dispersed nanotubes, which is reinforced during the decomposition process by the formation of a protective charred ceramic surface layer. The mechanism of action of HNTs for fire retardancy of PES presumably arises from a synergistic effect between physical (i.e. ceramic-like structure formation and mechanical reinforcement of the intumescent char) and chemical (i.e. charring promotion) processes taking place in the condensed phase. According to this study, the straightforward and cost-effective melt compounding route could pave the way for future development of high-performance nanoscale polymeric materials combining enhanced thermal properties and excellent flame retardant behaviour.     

Fire behaviour of polyamide 6/multiwall carbon nanotube nanocomposites

Nanocomposites of polyamide 6 with 5 wt.% multiwall carbon nanotubes are investigated to clarify their potential as regards the fire retardancy of polymers. The nanocomposites are investigated using SEM, electrical resistivity, and oscillatory shear rheology. The pyrolysis is characterized using thermal analysis. The fire behaviour is investigated with a cone calorimeter using different external heat fluxes, by means of the limiting oxygen index and the UL 94 classification. The fire residue is characterized using SEM. The comprehensive fire behaviour characterization not only allows the materials’ potential for implementation in different fire scenarios and fire tests to be assessed, but also provides detailed insight into the active mechanisms. The increased melt viscosity of the nanocomposites and the fibre-network character of the nanofiller are the dominant mechanisms influencing fire performance. The changes are found to be adjuvant with respect to forced flaming conditions in the cone calorimeter, but also deleterious in terms of flammability.     

Fire response of polyamide 6 with layered and fibrillar nanofillers

To improve the fire retardancy performance of polyamide 6 (PA 6), layered silicates are used in combination with multi-walled carbon nanotubes (CNTs) to address the issue of packing density and uniformity of the protective inorganic barrier formed at the burning surface of the nanocomposites during combustion. Benzimidazolium is used to modify the silicate layers instead of conventional alkyl ammonium surfactants to tackle the issue of thermal stability. However, the poor dispersion of the modified layered silicates in PA 6 has a significant negative effect on the fire performance of the materials and offsets the positive effect of CNTs. Also, the results point to the apparent contradictions with different fire exposure tests; that is, significant reductions in heat release and mass loss rates in the cone calorimetry test do not imply a higher rating in the UL 94 vertical burning test.     

Pyrolysis behavior of phosphorus polyesters

The pyrolysis behavior of aromatic–aliphatic polyesters containing either a pendant 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) group or a phosphine oxide group incorporated into the polymer backbone was studied using a combination of thermogravimetry and pyrolysis-GC/MS. The behavior of the phosphorus polyesters was compared to that of non-phosphorus-containing reference polymers. It could be shown that the DOPO group mainly does not interfere with the polyester decomposition. It produces two main pyrolysis products, o-hydroxybiphenyl and dibenzofuran, with the latter one requiring a higher pyrolysis temperature. Minor products containing the DOPO ring result from secondary decomposition reactions. In contrast, the phosphine oxide group strongly modifies the polyester pyrolysis behavior by decreasing the degradation temperature and changing the composition of pyrolysis products. Among of those, phosphinites and a phosphinate could be identified indicating rearrangement processes of the phosphine oxide group taking place upon pyrolysis. Mass spectra of organophosphorus products and pyrolysis schemes of polyesters are discussed.     

The effects of intralayer metal composition of layered double hydroxides on glass transition, dispersion, thermal and fire properties of their PMMA nanocomposites

A series of aluminum-containing layered double hydroxides (LDHs), containing Mg, Ca, Co, Ni, Cu and Zn as the divalent metals, have been prepared by the co-precipitation method and used to prepare nanocomposites of PMMA by in situ bulk polymerization. The additives were characterized by Fourier transform infrared spectroscopy, X-ray diffraction spectroscopy (XRD) and thermogravimetric analysis while the polymer composites were characterized by XRD, transmission electron microscopy, differential scanning calorimetry and cone calorimetry. Polymerization of methyl methacrylate in the presence of these undecenoate LDHs results in composites with enhanced thermal stability. The glass transition temperatures of the composites and the pristine polymers are found to be around 110 °C; this suggests that the presence of these additives has little effect on the polymer. It is found that the additive composition and the dispersion state of LDHs agglomerates in the polymer matrix influence the fire properties of composites as measured by cone calorimetry.     

New nanocomposites constituted of polyethylene and organically modified ZnAl-hydrotalcites

The thermal properties and combustion behaviour of new PE–hydrotalcites nanocomposites are described. Hydrotalcites were synthesized and then intercalated with stearate anion, because of the compatibility of long alkyl chain with polyethylene chains. The presence of inorganic filler shields PE from thermal oxidation, shifting the temperature range of volatilisation towards that of thermal degradation in nitrogen, and brings to a reduction of 55% in heat release rate during combustion.     

Incorporation of a flame retardancy enhancing phosphorus-containing diol into poly(butylene terephthalate) via solid state polycondensation: A comparative study

The phosphorus-containing aliphatic-aromatic diol 2-[4-(2-hydroxy-ethoxy)-3-(10-oxo-10-H9-oxa-10-λ5-phospha-phenanthrene-10-yl)-phenoxy]-ethanol, a potential flame retardant, was incorporated into poly(butylene terephthalate) (PBT) by solid state polycondensation. Thus, polymers with various ratios of PBT/DOPO-diol and number-average molar masses up to 57,000 g mol⁻¹ could be prepared. Their molar masses were higher than those of copolyesters with comparable composition obtained by direct melt polycondensation. Structures and properties of copolyesters produced by both methods were not significantly different after melt processing. Their thermal properties and combustion behaviour were investigated by means of DSC, TGA, and pyrolysis combustion flow calorimetry. Combustion studies revealed high char yields, very low heat release capacities and high limiting oxygen index (LOI) at rather low P-contents, indicative of better flame-retardancy properties.     

Pyrolysis and fire behaviour of epoxy resin composites based on a phosphorus-containing polyhedral oligomeric silsesquioxane (DOPO-POSS)

The pyrolysis and fire behaviour of epoxy resin (EP) composites based on a novel polyhedral oligomeric silsesquioxane containing 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO-POSS) and diglycidyl ether of bisphenol A (DGEBA) have been investigated. The pre-reaction between the hydroxyl groups of DOPO-POSS and the epoxy groups of DGEBA at 140 °C is confirmed by FTIR, which means that DOPO-POSS molecules of hydroxyl group could easily disperse into the epoxy resin at the molecular level. The EP composites with the DOPO-POSS were prepared through a curing agent, m-phenylenediamine (m-PDA). The morphologies of the EP composites observed by SEM indicate that DOPO-POSS disperses with nano-scale particles in the EP networks, which implies good compatibility between them. The thermal properties and pyrolysis of the EP composites were analyzed by DSC and TGA, TGA-FTIR, and TGA-MS. The analysis indicates that the DOPO-POSS change the decomposition pathways of the epoxy resin and increase its residue at high temperature; moreover, the release of phosphorous products in the gas phase and the existence of Si-O and P-O structures in the residue Is noted. The fire behaviour of the EP composites was evaluated by cone calorimeter (CONE). The CONE tests show that incorporation of DOPO-POSS into epoxy resin can significantly improve the flame retardancy of EP composites. SEM and XPS were used to explore micro-structures and chemical components of the char from CONE tests of the EP composites, they support the view that DOPO-POSS makes the char strong with the involvement of Si-O and P-O structures.     

A novel phosphorus-containing copolyester/montmorillonite nanocomposites with improved flame retardancy

A novel phosphorus-containing flame-retardant copolyester/montmorillonite nanocomposite (PET-co-HPPPA/O-MMT) was synthesized by the in situ intercalation polycondensation of terephthalic acid, ethylene glycol, and 2-carboxyethyl(phenylphosphinic) acid (HPPPA) with montmorillonite (O-MMT). The morphology was characterized by wide-angle X-ray diffraction, scanning electron microscopy and transmission electron microscopy. The effects of organoclay on the thermal properties and melting behaviors of the nanocomposites were investigated by thermogravimetric analysis and differential scanning calorimetry. The flammability of the nanocomposites was characterized by the limiting oxygen index test and the UL-94 vertical test. The results showed that a small amount of organoclay was able to improve the thermal stabilities and the flame retardancy of PET-co-HPPPA copolyesters, and however there was no significant increase in the melting points of nanocomposites when the content of diethylene glycol was controlled as a certain value. The overall crystallization rate of the nanocomposites is greater than that of neat copolyester. The nanocomposites have better flame retardancy than PET-co-HPPPA.     

Structural characterization and thermal decomposition of layered double hydroxide/poly(p-dioxanone) nanocomposites

Nanocomposites based on layered double hydroxides (LDH) and poly(p-dioxanone) (PPDO) were prepared by melt processing using dodecylbenzene sulfonate (DBS) and 4-hydroxybenzene sulfonate (HBS) as organic modifiers. The incorporation of organic anions in LDH was demonstrated by wide-angle X-ray scattering (WAXS) and Fourier transform infrared (FTIR). The dispersion degree of the organically modified LDHs in the PPDO matrix was analyzed by WAXS, indicating that only the LDH modified with HBS was exfoliated. The effect of the organically modified LDHs on the thermal stability of PPDO was studied using thermogravimetric analysis (TGA). The thermal stability of PPDO matrix was enhanced by the incorporation of the LDH modified with HBS due to the shielding effect of the exfoliated layers. In contrast, the LDH modified with DBS produced a decrease of the thermal stability of PPDO, probably due to hydrolytic decomposition of ester group. The thermogravimetric analysis also showed that the organo-modified LDH did not modify the thermal decomposition mechanism of the polymer, but had an effect on the thermal stability.     

Thermal and combustion behavior of polyethersulfone-boehmite nanocomposites

In this paper, we report a thorough study on the thermal stability and fire behavior of polyethersulfone (PES) filled with 2 wt% nano-sized aluminum oxide hydroxide particles (boehmite). The nanocomposite was prepared through melt compounding technique in a co-rotating twin screw extruder. The obtained morphology of the composite was studied by scanning electron microscopy (SEM) coupled with elemental analysis, proving that an even distribution of sub-micron boehmite particles was obtained. PES shear modulus, measured by DMA, is increased by 30% in the boehmite nanocomposite. Thermal stability of the produced materials was studied through thermal gravimetric analysis (TGA), whereas the combustion behavior through cone calorimeter and vertical burning (UL-94) tests. Cone calorimeter results show that a significant overall flame retardant effect was observed due to the presence of boehmite nanoparticles, which could not be detected by UL-94 fire scenario where neat PES is already top ranked V0.     

Factors and processes influencing the reinforcing effect of layered silicates in polymer nanocomposites

The analysis of the tensile yield stress of a large number polymer/layered silicate composites showed widely differing mechanical properties. The composition dependence of yield stress can be described and evaluated quantitatively by a simple model developed earlier for particulate filled polymers. The comparison of data produced in our laboratory or taken from the literature indicated that several processes may take place during the preparation of the composites and a considerable number of factors influence composite properties. Quite a few of these are often neglected and percentage increase in modulus, strength or other properties is reported in published papers instead. The most important of such effects are changing matrix properties when a functionalized polymer is used to promote adhesion (PE, PP), modification of crystalline structure due to nucleation (PA, PP), plasticization or lubrication (PVC), decreased interaction (PA, PVC, PET, rubbers) or chemical reactions (PVC, PP, PET). Using a few simple assumptions, most of which are supported by previous experience, the extent of exfoliation can be estimated quantitatively in nanocomposites. The analysis of the tensile yield stress of more than 80 composites with various matrices indicated that the extent of exfoliation is very low in most composites; it reaches maximum 10% in the best case, which corresponds to about 10 silicate layers per stack. Although the approach has limitations and several factors were neglected during analysis, this result is in agreement with observations indicating that complete exfoliation rarely can be reached in thermoplastic/clay composites. In order to achieve larger reinforcement, silicates must be exfoliated more perfectly in the future.     

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.     

The absence of size-dependency in flame retarded composites containing low-melting organic-inorganic glass and clay: Comparison between micro- and nanocomposites

Due to optimised processing of epoxy based composite materials containing a low-melting organic-inorganic glass together with an organo clay, the size of the glass particles could be successfully reduced. Thus truly nano-dispersed composites were obtained, with glass particles in the range of 10 nm to 200 nm. The small particle size allowed efficient interaction of glass particles and organo clay layers. The flame retardancy as well as the thermo-mechanical properties were tested, and the results showed that the low-melting glass led to a remarkable reduction of peak heat release rate by forming an enhanced barrier layer. Nevertheless no further improvement could be achieved by lowering the particle size to the nanometre region. For good flame retardancy a microdispersion of the low-melting glass was already sufficient.     

Structure-property relationships of new polystyrene nanocomposites prepared from initiator-containing layered double hydroxides of zinc aluminum and magnesium aluminum

Polystyrene/layered double hydroxides (PS/LDHs) nanocomposites were prepared by free radical polymerization of styrene monomer in the presence of LDHs intercalated with 4,4′-azobis(4-cyanopentanoate) anions (LDH-ACPA). XRD and ATR-IR are used to confirm that the materials produced are layered and the presence of the azo-initiator anions in these LDHs. These LDHs were used successfully to polymerize styrene and both XRD and TEM images of the composites support the formation of a mixed exfoliated-intercalated nanocomposite for ZnAl-ACPA but a microcomposite for MgAl-ACPA. The magnesium-containing LDHs decreased the glass transition temperature (T_g) of the composites while ZnAl-ACPA did not affect T_g significantly. The T_g depression is related to enhanced polymer dynamics due to the extra free volume at the LDH additive-polymer interface. A reduction in the onset of thermal decomposition temperature was observed in PS/LDH compared to neat PS, likely due to the early decomposition of the LDH. The fire performance, as evaluated by the cone calorimeter, reveal that PS-ZnAl-ACPA shows enhanced fire properties compared to PS-MgAl-ACPA.     

Pyrolysis products and thermal degradation mechanism of intrinsically flame-retardant calcium alginate fibre

Intrinsically flame-retardant calcium alginate fibre was prepared by wet spinning and its pyrolysis products and thermal degradation mechanism studied. Combustion behaviour and flammability were assessed using the limiting oxygen index (LOI) and cone calorimetry. LOI results showed that calcium alginate fibre was intrinsically flame retardant with LOI value of 48.0, as compared to about 20.0 for viscose fibre. Cone calorimetry indicated that heat release rate and total heat release values of intrinsically flame-retardant fibre were significantly less than those of viscose fibre. It also shown that intrinsically flame-retardant fibre combustion produced greater quantities of residues than did viscose fibre combustion. Combustion residues were examined using scanning electron microscopy, indicating that calcium alginate fibre produced consistent, thick residue crusts. Pyrolysis was investigated using pyrolysis-gas chromatography-mass spectrometry (Py-GC-MS) which showed that cracking products produced from calcium alginate fibres combustion were less than those in viscose fibre combustion, and pyrolysis of the intrinsically flame-retardant fibre was incomplete. Thermogravimetric analysis (TG) indicated that calcium alginate fibre generated more residues containing carbonaceous char and calcium carbonate, as compared with viscose fibre. We propose a condensed phase mechanism for the calcium alginate fibre flame-retardancy effect.     

Polyamide 6 treated with pentabromobenzyl acrylate and layered silicates

A study of the simultaneous application of a brominated flame retardant and an organically layered silicate (OLS) for the flame retarding of polyamide 6 (PA6) is presented. Upon treating PA6 with at least 7 wt% monomeric pentabromobenzyl acrylate (PMA), a UL‐94 V‐0 rating and an oxygen index (OI) value of 29.7 were obtained. By adding 1 wt% organically layered montorillonite (OMMT) and 10 wt% PMA, the V‐0 rating remained, indicating cooperation between PMA and OMMT. Higher concentrations of OMMT result in a decreased UL‐94 rating showing an antagonism. The size and mass of drops formed in the UL‐94 test increased with increasing OMMT, suggesting an increase in the viscosity and density of the pyrolyzing matrix. The effect of the Br additive on the peak heat release rate (PHRR) measured in the cone calorimeter is similar, but smaller, than that of clay. A calculation of the synergistic effectivity related to PHRR enabling a numerical estimate of the extent of synergism or antagonism is presented. When the ill‐dispersed pristine clay (Na⁺MMT) is used, the viscosity does not increase, the PHRR decreases slightly, but the mass loss rate (MLR) is close to that of the matrix. The time of ignition (TOI) decreases upon the addition of PMA, similarly to the addition of OMMT. This is explained by migration of the Br additive to the surface barrier similar to that of clay so that the low thermal conductivity (TC) barrier is formed before the ignition. Accumulation of heat in the barrier decreases the TOI. Copyright © 2010 John Wiley & Sons, Ltd.