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Synergistic effects of mono-component intumescent flame retardant grafted with carbon black on flame retardancy and smoke suppression properties of epoxy resins

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Abstract

A mono-component intumescent flame retardant named pentaerythritol phosphate melamine salt (PPMS) was grafted on the surface of carbon black (CB) to obtain PPMS-grafted CB (PPMS-CB). The obtained PPMS-CB was well characterized and then incorporated into epoxy resins (EPs) to investigate flame retardancy and smoke suppression properties. Thermo-gravimetric analysis indicates that the synergism between PPMS and CB could improve the char-forming ability of EP composites. Limiting oxygen index (LOI) and UL94 vertical burning tests reveal that EP composite with 15 mass% PPMS-CB achieves a LOI value of 26.2% and passes the UL94 V-1 rating, while the same addition of PPMS only achieves a UL94 V-2 rating and LOI value of 22.7%. Cone calorimeter and smoke density tests show that the incorporation of PPMS-CB obviously decreases the heat release and smoke production of EPs, for example, 66.9% reduction in peak heat release rate, 54.3% reduction in peak smoke production rate and 36.5% reduction in smoke density rating, are observed in the case of EP composite with 15 mass% PPMS-CB. The excellent performance of EP/PPMS-CB composites can be ascribed to the formation of more cross-linking structures containing N and P in the condensed phase, thus producing a more compact and continuous char that acts as a thermally stable barrier against the heat and mass transfer. Overall, the chemical combination of PPMS and CB provides a new approach to develop highly efficient mono-component intumescent flame retardant and corresponding super flame-retarded polymer materials.

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (No. 51676210), the Hunan Provincial Natural Science Foundation of China (No. 2018JJ3668) and China Postdoctoral Science Foundation (No. 2017M612587).

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Authors and Affiliations

  1. School of Civil Engineering, Central South University, Changsha, 410075, China

    Long Yan, Zhisheng Xu, Nan Deng & Zhiyong Chu

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  1. Long Yan
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  2. Zhisheng Xu
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Correspondence to Long Yan.

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Yan, L., Xu, Z., Deng, N. et al. Synergistic effects of mono-component intumescent flame retardant grafted with carbon black on flame retardancy and smoke suppression properties of epoxy resins. J Therm Anal Calorim 138, 915–927 (2019). https://doi.org/10.1007/s10973-019-08298-2

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  • DOI: https://doi.org/10.1007/s10973-019-08298-2

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