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Most synthetic polymers have a high fire load, and as a result, they require flame retardants (FRs) to ensure their safe use. Phosphorus plays an important role in flame retardancy and has the potential to replace halogenated variants, which are assumed to be harmful to the environment and health. Among phosphorus-based FRs, there exists a trend towards polymeric, high molar mass molecules with complex molecular architectures. In this project, we synthesized a novel series of so-called phosphorus-based hyperbranched polymeric FRs and investigated their use as multifunctional additives to high-performance polymers, i.e. epoxy resins. By cleverly designing the chemical structure to contain varying amounts of P-O and P-N bonds, new insight into the chemical mechanism of flame retardancy was gained, and by comparing the hyperbranched polymers to their monomeric counterparts, a greater understanding of the role of complex architecture was won. This talk aims at presenting some of these results and proposes chemical mechanisms that illustrate what role these novel hyperbranched flame retardants play in molecular firefighting.
In this study, the thermal decomposition of 1,3,5-tris-(2,3-dibromopropyl)-1,3,5-triazine-2,4,6-trione (TDBPTAZTO) and 2,4,6-tris-(2,4,6-tribromo-phenoxy)-1,3,5-triazine (TTBP-TAZ) were investigated for the first time by thermogravimetric analysis. Both compounds were thermal degraded between 225 and 350 °C (TDBP-TAZTO) as well as 300 and 400 °C (TTBP-TAZ).
As a result, mass loss (%) of 98.5% for TTBP-TAZ and 95.4% for TDBP-TAZTO at 600 °C under N2 were observed. The major pyrolytic degradation products of TTBP-TAZ were formed in a single step and identified by FTIR analysis as 2,4,6-tribromophenol and further bromine-substituted aromatic compounds. In comparison, TDBP-TAZTO was pyrolytic degraded in two steps, whereby on the first step the release of hydrogen Bromide and 1,3,5-triallyl-1,3,5-triazine-2,4,6-trione could be detected. In the second minor step, isocyanic acid could be additionally identified.
Subsequently, the obtained products of the TGA-FTIR measurements were used for a targeted search for mass fragments in mass spectrometry measurements. For TTBP-TAZ, only the degradation product 1,3,5-tribromobenzene could be detected by MS/MS analyzes. No comparable thermal degradation products, except hydrogen bromide, were observed in the MS/MS spectra of TDBP-TAZTO. Therefore, the search of further mass fragments was not possible compared to the findings of the TGA-FTIR measurements.
This paper is based mainly on the results of two different projects performed in the group of the author recently (2016-2019). The three external partners involved in these two projects are competent in the preparation of FPUF (ICL IP America), RPUF (Department of Industrial Engineering, Padova University), and TPU (Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF, Darmstadt) as well as for the specimen preparation. Systematically varied sets of materials were prepared as the key basic for scientific discussion, varying the kind and combination of flame retardant, PUR structure, density, and blowing agent.
A multimethodical approach based on thermogravimetry (TGA), TGA coupled with evolved gas analysis (TGA-FTIR) and pyrolysis GC-MS was used for investigating the pyrolysis. The flammability was addressed using oxygen index (OI) and testing in UL 94 burning chamber in vertical and horizontal set-up. The fire behaviour was addressed by using a cone calorimeter. Beyond these methods according to the state of the art, key experiments were performed. We addressed the dripping and the two-stage burning of TPU using a self-designed apparatus and specific data evaluation, the foam burning through quenching burning samples, using different special sample holders, and measuring temperature profiles within the burning foams. The investigation is made round by intensive analysis of the fire residues, such as comprehensive investigation of the morphology.
Result on the pyrolysis (TGA-FTIR, Pyrolysis-GC/MS), flammability (UL 94, LOI), and fire behaviour (cone calorimeter) of TPU and flame retardant TPUs are shown. We discuss in detail the characteristic of PUR decomposition: the low tendency to char, and the specific two step decomposition and how these characteristics control the regimes in fire behaviour. We demonstrate that the different burning regimes are controlled by different pyrolysis products and effective heat of combustions. The resulting formation of pool fires as well as the formation of dripping is discussed in detail. The latter quite important to understand the flame retardancy applied with respect to achieve the UL 94 classification V0 nondripping or V0 non-flaming dripping.
Rigid and flexible PUR foams and their flame retarded versions are investigated for different densities. Water and pentane-blown foams are compared as well as PUR and polyisocyanurate-polyurethane (PIR) foams. Horizontal testing in the cone calorimeter is used and the vertical foam specimen holder as well. Self-designed set-ups within the cone calorimeter enable a better inside in the pyrolysis front running through the foam samples as well as the development of the temperature gradient inside the foam during the fire test. The morphology change during burning was characterised by the means of quenching burning foams with liquid nitrogen and investigating the cross sections with scanning electron microscope. In sum, a rather comprehensive study was performed to work out the principle fire phenomena controlling the fire behaviour of PUR foams in a very systematic and significant way.
Promising flame retardancy approaches are discussed. The importance of either combining the drain of fuel and flame inhibition or charring into an effective protection layer/multicellular structure is underlined.
This contribution focusses the general conclusions and trends. It tries to increase the understanding of the specific and demanding challenge to develop flame retardant PUR materials.
The presentation gives an overview of actual research adtivities in the field of flame retardant polymers. Details are selected illuminating the scientific topic beyond the state of the art. Different concepts are illustrated with own results obtained in different Research projects over the last 15 years.