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Flame Retardant Mechanisms of Red Phosphorus and Magnesium Hydroxide in High Impact Polystyrene
(2004)
The flame retardant mechanisms of red phosphorus, magnesium hydroxide and red phosphorus combined with magnesium hydroxide were studied in high impact polystyrene by means of comprehensive decomposition studies and combustion tests. The study is intended to illuminate prerequisites and the potential of red phosphorus as a fire retardant for hydrocarbon polymers in the condensed phase and in the gas phase. Thermal and thermo-oxidative decomposition, decomposition kinetics and the product gases evolved were characterized using thermogravimetry coupled with Fourier transform infrared spectroscopy and mass spectroscopy, respectively. Fire behaviour was investigated with a cone calorimeter using different external heat fluxes, whereas the flammability was determined by limited oxygen indices. The combustion residues were analysed using XPS. Red phosphorus reduced the heat release in HIPS due to radical trapping in the gas phase. Magnesium hydroxide influenced fire behaviour by heat sink mechanisms, release of water and the formation of a magnesia layer acting as a barrier. The combination of both flame retardants in HIPS nearly resulted in a superposition. A slight synergy in barrier characteristics was due to the formation of magnesium phosphate, whereas a slight anti-synergism occurred in flammability and in the gas phase action. The latter effect is controlled by a decreased fuel rate due to the barrier layer rather than by an initiation of red phosphorus oxidation in the condensed phase.
The flame retardancy mechanisms of three aryl phosphates, triphenyl phosphate (TPP), resorcinol bis(diphenyl phosphate) (RDP) and bisphenol A bis(diphenyl phosphate) (BDP), in a polycarbonate/acrylonitrile-butadiene-styrene (PC/ABS) blend are investigated and compared. Further, the influence of polytetrafluorethylene (PTFE) on viscosity and thermal decomposition is discussed in the systems PC/ABS and PC/ABS + BDP. Mechanisms are proposed based on the results of various methods. Thermogravimetric analysis, Fourier transform infrared spectroscopy and kinetics are used to study the pyrolysis. The fire behaviour is studied by means of cone calorimeter measurements at different heat fluxes and the flammability is specified by limiting oxygen index (LOI) and UL 94. Rheology measurements are used to illuminate the changed dripping behaviour due to PTFE. TPP shows only a gas phase action. RDP shows mainly a gas phase action and some condensed phase action. BDP shows a crucial condensed phase action in addition to a gas phase action. TPP and RDP are somewhat superior in terms of flammability (LOI), whereas BDP shows superior performance in forced flaming combustion (cone calorimeter). Synergistic effects between PTFE and BDP are found.
The pyrolysis of an epoxy resin and the fire behavior of corresponding carbon fiber-reinforced composites, both flame-retarded with either 10-ethyl-9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide or 1,3,5-tris[2-(9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide-10-)ethyl]1, 3,5-triazine-2,4,6(1H,3H,5H)-trione, are investigated. The different fire retardancy mechanisms are discussed, and their influence on the fire properties assessed, in particular for flammability (limiting oxygen index, UL 94) and developing fires (cone calorimeter with different external heat fluxes of 35, 50, and 70 kW m-2). Adding the flame retardants containing 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide affects the fire behavior by both condensed phase and gas phase mechanisms. Interactions between the additives and the epoxy resin result in a change in the decomposition pathways and an increased char formation. The release of phosphorous products results in significant flame inhibition. The fire properties achieved are thus interesting with respect to industrial exploration.
The pyrolysis and fire behavior of glass-fiber reinforced poly(butylene terephthalate) (PBT/GF) with two different metal phosphinates as flame retardants in combination with and without melamine cyanurate (MC) were analyzed by means of thermogravimetry, thermogravimetry coupled with infrared spectroscopy, flammability, and cone calorimeter tests as well as scanning electron microscopy/energy dispersive X-ray spectroscopy and X-ray fluorescence spectroscopy. In PBT/GF, dosages of 13-20% of the halogen-free flame retardant aluminum phosphinate or aluminum phosphinate in combination with MC fulfill the requirements for electrical engineering and electronics applications (UL 94 = V-0; LOI > 42%), whereas the use of the same amount of zinc phosphinate or zinc phosphinate in combination with MC does not improve the fire behavior satisfactorily (UL 94 = HB; LOI = 27-28%). The performance under forced flaming conditions (cone calorimeter) is quite similar for both of the metal phosphinates. The use of aluminum and zinc salts results in similar flame inhibition predominantly due to the release of the phosphinate compounds in the gas phase. Both metal phosphinates and MC interact with the polymer changing the decomposition characteristics. However, part of the zinc phosphinate vaporizes as a complete molecule. Because of the different decomposition behavior of the metal salts, only the aluminum phosphinate results in a small amount of thermally stable carbonaceous char. In particular, the aluminum phosphinate-terephthalate formed is more stable than the zinc phosphinate-terephthalate. The small amount of char has a crucial effect on the thermal properties and mechanical stability of the residue and thus the flammability.
The flame retardancy mechanisms of aluminium diethylphosphinate (AlPi) and its combination with melamine cyanurate (MC) in glass-fibre-reinforced poly(butylene terephthalate) (PBT/GF) were analysed using TGA including evolved gas analysis (TGA-FTIR), cone calorimeter measurements using various irradiations, flammability tests (limited oxygen index, LOI, UL 94) and chemical analyses of residues (FTIR, SEM/EDX). AlPi decomposed mainly through the formation of diethylphosphinic acid and aluminium phosphate and influenced the decomposition of the PBT only slightly. AlPi acted mainly through flame inhibition. A halogen-free V-0 PBT/GF material was achieved with a LOI of 44%. Additional charring influenced the flammability. MC decomposed independently of the polymer and showed some fuel dilution effects.
In this first of two papers, the thermal decomposition of bisphenol A bis(diphenyl phosphate)-flame retarded polycarbonate (PC) blends with different impact modifiers was studied. The impact modifiers were an acrylonitrile-butadiene-styrene (ABS), a poly(n-butyl acrylate) (PBA) rubber with a poly(methyl methacrylate) (PMMA) shell and two silicone-acrylate rubbers consisting of PBA with different amounts of polydimethylsiloxane (PDMS) and different shells (PMMA and styrene-acrylonitrile, SAN). The focus of this work was to study the impact of the acrylate and silicon-acrylate rubbers with respect to pyrolysis and flame retardancy in comparison to common ABS. Thermogravimetry (TG) was performed to investigate the pyrolysis behaviour and reaction kinetics. TG in combination with FTIR identified the pyrolysis gases. Solid residues were investigated by FTIR-ATR. PC/ABS shows two-step decomposition, with PC decomposing independently from ABS at higher temperatures. Pure acrylate rubber destabilises PC due to interactions between the rubber and PC, which leads to earlier decomposition of PC. Using silicone-acrylate rubbers led to similar results as PC/ABS with respect to pyrolysis, reaction kinetics and analysis of the solid residue; hence the exchange of ABS for the silicone-acrylate rubbers is possible.
On the basis of two examples, temperature measurements are proposed within burning polymer specimen during the cone calorimeter test; especially to gain deeper insight into the actual pyrolysis conditions and flame retardancy mechanism. The heating and pyrolysis within a poly(methyl methacrylate) specimen were characterized, discussing the characteristic maximum heating rates (165-90°Cmin-1 decreasing with depth within the specimen and >275°Cmin-1 at the initial surface), pyrolysis temperature (454-432°C decreasing in accordance with decreasing heating rates), thickness of the pyrolysis zone (0.5-1.3 mm) and its velocity (1.2-2.1 mm min-1) as a function of sample depth and burning time. Thermally thick behaviour corresponds to a pyrolysis zone thickness of 0.74 mm and a velocity of 1.51 mm min-1 and occurs until the remaining specimen thickness is less than 8 mm. The shielding effect against radiation occurring in a layered silicate epoxy resin nanocomposite was investigated. It is the main flame retardancy effect of the silicate-carbon surface layer formed under fire. The reradiation from the hot surface is increased by a factor of around 4-5 when an irradiance of 70kWm-2 is applied. The energy impact into the pyrolysis zone is crucially reduced, resulting in a reduction of fuel production and thus heat release rate.
The pyrolysis and fire behavior of halogen-free flame-retarded DGEBA/DMC, RTM6 and their corresponding 60 vol.-% carbon fibers (CF) composites were investigated. A novel phosphorous compound (DOPI) was used. Its action is dependent on the epoxy matrix. DGEBA/DMC and DOPI decompose independently of each other. Only flame inhibition occurs in the gas phase. RTM6 shows flame inhibition and a condensed phase interaction increasing charring. Both mechanisms decrease with increasing irradiance, whereas in RTM6-CF charring is suppressed at low ones. RTM6+DOPI shows a higher LOI (34.2%) than DGEBA/DMC+DOPI and a V-0 classification in UL 94. Adding CF only enhances the LOI, DOPI+CF leads to a superposition in LOI for DGEBA/DMC-CF+DOPI (31.8%, V-0) and a synergism for RTM6-CF+DOPI (47.7%, V-0).