Synthesis and surface modification of nanophosphorous-based flame retardant agent by continuous flow hydrothermal synthesis

Nanoparticles can provide flame retardance to hosting polymers and act as nano fire extinguishers. Hydroxyapatite (Ca₅(OH)(PO₄)₃) (HA) is not hygroscopic, and is thermally stable up to 800 °C, with 18.5 wt% phosphorous content. It is this high phosphorous content that can provide HA with flame retardant properties. In this paper, we report on the continuous synthesis of ultrafine HA using a hydrothermal synthesis technique. The HA surface properties were changed from hydrophilic to hydrophobic by post-synthesis surface modification. The ratio of the HA nanoparticles and an intumescent agent known as Exolit AP750 was investigated to yield a self-extinguishing multi-component epoxy nanocomposite for extended application under extreme fire conditions. The HA/AP750/epoxy nanocomposite was able to resist a flame at 1700 °C and self-extinguish after the flame had been removed. The nanocomposite showed an enhanced flammability performance in standard cone calorimetry testing and formed a compact and cohesive protective char layer with a 50% decrease in peak heat released compared with virgin epoxy. Our aim was to establish the use of HA as an effective nanofiller with phosphorous-based flame retardant properties. The surface of this nano fire extinguisher was modified effectively with different surfactants for enhanced compatibility with different polymeric matrices.