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A systematic and comparative evaluation of the pyrolysis of halogen-free flame-retarded epoxy resins containing phosphine oxide, phosphinate, phosphonate, and phosphate (phosphorus contents around 2.6 wt.%) and the fire behaviour of their carbon fibre composites is presented. Decomposition pathways are proposed based on the thermal analysis (TG), TG coupled with evolved gas analysis (TG-FTIR), kinetics and analysis of the residue with FTIR and XPS. All organophosphorus-modified hardeners containing phenoxy groups lead to a reduced decomposition temperature and mass loss step for the main decomposition of the cured epoxy resin. With increasing oxidation state of the phosphorus the thermally stable residue increases, whereas the release of phosphorus-containing volatiles decreases. The flammability of the composites was investigated with LOI and UL 94 and the fire behaviour for forced-flaming conditions with cone calorimeter tests performed using different irradiations. The flame retardancy mechanisms are discussed. With increasing oxidation state of the phosphorus additional charring is observed, whereas the flame inhibition, which plays the more important role for the performance of the composites, decreases. The processing and the mechanical performance (delamination resistance, flexural properties and interlaminar bonding strength) of the fibre-reinforced composites containing phosphorus were maintained at a high level and, in some cases, even improved. The potential for optimising flame retardancy while maintaining mechanical properties is highlighted in this study.
Highly soluble 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide-(DOPO)-based diamino hardener (2), bearing its amino groups directly on the DOPO framework, is investigated with respect to its use as a reactive flame retardant in thermosets. A mechanism for decomposition of the corresponding phosphorus-modified epoxy resin system based on a diglycidylether of bisphenol A DGEBA and 2 (DGEBA/2) is proposed and compared to the systems using DGEBA and 4,4'-diaminodiphenylsulfon (DGEBA/DDS) and to a similar system based on the structurally comparable non-reactive DOPO-based compound (DGEBA/DDS/1). Additive 1 changed the decomposition characteristics of the epoxy resin only slightly and phosphorus was released. Incorporating 2 induces two-step decomposition and most of the phosphorus remains in the residue. Furthermore, the fire behaviour of neat epoxy resin systems and a representative carbon fibre-reinforced composite based on DGEBA, DDS and 2 (DGEBA/DDS/2) were examined and compared to that of the analogous composite systems based on DGEBA/DDS and DGEBA/DDS/1. Based on different flame retardancy mechanisms both the reactive compound 2 and the additive compound 1 improve flammability (increase in LOI >13% and achieving V-1 behaviour) of the epoxy resin and composites. Under forced flaming only the flame inhibition of the additive compound 1 acts sufficiently. Lastly, the superior key mechanical properties of the epoxy resin and composite based on 2 are sketched.
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.