Yong Qiuab,
Zhen Liub,
Lijun Qian*b and
Jianwei Hao*a
aNational Laboratory of Flame Retardant Materials, National Engineering and Technology Research Center of Flame Retardant Materials, School of Materials Science and Engineering, Beijing Institute of Technology, Beijing 100081, P. R. China. E-mail: hjw@bit.edu.cn
bEngineering Laboratory of Non-halogen Flame Retardants for Polymers, School of Materials Science and Mechanical Engineering, Beijing Technology and Business University, Beijing 100048, P. R. China. E-mail: qianlj@th.btbu.edu.cn
First published on 3rd November 2017
A multi-phosphaphenanthrene compound (TDBA) was incorporated into polycarbonate (PC) to prepare a flame retardant composite. TDBA improved the flame retardancy of the PC material effectively. The PC composite comprising 10 wt% TDBA passed the UL94 V-0 level with a LOI value of 33.7%. The incorporation of TDBA effectively inhibited the combustion intensity of the TDBA/PC composite via reducing the production of flammable methane and carbonyl-containing substances, suppressing the oxidative process of combustible pyrolysis products, and promoting the PC matrix to form large-scale smoke particles. All these were caused by releasing phosphaphenanthrene fragments, PO, and phenoxyl free radicals from pyrolyzed TDBA. As an additive-type flame retardant with multiple phosphaphenanthrene groups, TDBA was verified to exert its effect mainly in the gaseous phase during flame retarding of PC materials.
In recent years, great efforts have been invested into the research of flame retardant treatments on PC materials.14–17 Undoubtedly, intermingling with additive-type flame retardants is the most convenient and workable strategy to improve the flame retardancy of PC materials.18,19 Based on this cognition, massive effective flame retardants have been developed and applied in flame retarding PC materials, including halogen-containing,20 sulphonate-containing,21,22 organosilicon-containing,23 phosphorus-containing compounds,24 inorganic additives,25 and nanomaterials.26,27 Recently, as a promising intermediate in developing novel halogen-free flame retardants, 9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide (DOPO) have been frequently used to synthesize effective and efficient phosphaphenanthrene-containing flame retardant additives for various polymer materials.28–33 And some similar works have also suggested that the addition of phosphaphenanthrene-containing additive indeed improved the flame retardancy of PC materials effectively.34 Hence, the research on the phosphaphenanthrene-containing compound flame retarding PC materials is worth further exploring and investigating.
In this thesis, an additive-type, four-arm star-shaped, and multi-phosphaphenanthrene flame retardant compound (TDBA,35 shown in Fig. 1) is looking forward to improve the flame retardancy of PC materials effectively due to its multiple phosphaphenanthrene groups (flame retardant segment, shown in Fig. 1). The limited oxygen index (LOI) measurement, vertical burning test, and cone calorimeter test were adopted to evaluate the flammability and combustion behavior of composites. Meanwhile, the thermogravimetry-Fourier transform infrared spectroscopy (TG-FTIR) analyzed the influence of TDBA on the decomposition of PC matrix, and also monitored the structural characteristic of evolved gases during TG procedure. Furthermore, the pyrolysis-gas chromatography/mass spectrometry (Py-GC/MS) analysis on PC composites was also adopted to reveal the influence of TDBA on the detailed pyrolysis products of PC matrix. Through above results and discussion, the action mode and mechanism of TDBA in flame retarding PC materials were sufficiently explored.
Samples | PC (g) | TDBA | Phosphorus content (wt%) | |
---|---|---|---|---|
(g) | (wt%) | |||
PC | 200 | — | — | — |
6% TDBA/PC | 188 | 12 | 6 | 0.58 |
8% TDBA/PC | 184 | 16 | 8 | 0.77 |
10% TDBA/PC | 180 | 20 | 10 | 0.96 |
Samples | LOI (%) | Vertical burning test | ||||
---|---|---|---|---|---|---|
Afterburning time | UL94 level | Dripping | Ignition | |||
t1 (s) | t2 (s) | |||||
PC | 26.2 ± 0.1 | 27.3 ± 2.0 | 8.4 ± 3.5 | V-2 | Yes | Yes |
6% TDBA/PC | 30.3 ± 0.2 | 5.9 ± 2.4 | 4.2 ± 1.8 | V-2 | Yes | Yes |
8% TDBA/PC | 31.3 ± 0.2 | 0.9 ± 0.5 | 1.2 ± 0.2 | V-2 | Yes | Yes |
10% TDBA/PC | 33.7 ± 0.1 | 0.7 ± 0.1 | 1.0 ± 0.5 | V-0 | Yes | No |
Fig. 2 Photos of the PC composite specimens after LOI measurement (A) and vertical burning test (B). (a) PC, (b) 6% TDBA/PC, (c) 8% TDBA/PC, and (d) 10% TDBA/PC. |
Apparently, the addition of TDBA effectively inhibited the combustion of PC materials. Only 6 wt% TDBA elevated the LOI value of composite from 26.2% in neat PC to 30.3% in 6% TDBA/PC. With increasing TDBA loading from 6 wt% to 10 wt%, the LOI of TDBA/PC composite was gradually further elevated to higher values. In 10% TDBA/PC, the highest LOI value 33.7% was achieved within this research range. Meanwhile, the results of vertical burning test also demonstrated that the incorporation of TDBA contributed greatly to shortening the afterburning time of TDBA/PC composite after both of the first and second flame applications. And, also in the case of 10 wt% loading, TDBA endowed PC material passed UL94 V-0 level. Besides, the photos of LOI and vertical burning test residue suggested that TDBA worked on the combustion of PC material mainly via gaseous-phase action, rather than condensed-phase one. Because less char residue was reserved on the burnt specimen, as shown in Fig. 2. The remarkable flame retardant performance of TDBA-containing composites in LOI and UL94 level evaluation indicates that, TDBA is capable to improve the flame retardancy of PC materials effectively.
Samples | pk-HRR (kW m−2) | av-EHC (MJ kg−1) | THR (MJ m−2) | TSP (m2) | av-COY (kg kg−1) | av-CO2Y (kg kg−1) | Residue (wt%) |
---|---|---|---|---|---|---|---|
PC | 800 ± 19 | 32.5 ± 0.4 | 113 ± 1 | 32.0 ± 1.5 | 0.15 ± 0.00 | 2.81 ± 0.05 | 17.3 ± 1.0 |
6% TDBA/PC | 643 ± 10 | 27.5 ± 0.7 | 104 ± 4 | 43.1 ± 0.1 | 0.21 ± 0.01 | 2.34 ± 0.04 | 15.6 ± 0.5 |
8% TDBA/PC | 626 ± 11 | 26.5 ± 0.5 | 98 ± 3 | 47.9 ± 0.2 | 0.24 ± 0.02 | 2.21 ± 0.05 | 14.6 ± 0.1 |
10% TDBA/PC | 566 ± 7 | 24.2 ± 0.5 | 92 ± 2 | 49.6 ± 0.4 | 0.24 ± 0.01 | 2.07 ± 0.02 | 12.8 ± 0.8 |
As shown in Fig. 3, the addition of TDBA suppressed the combustion of TDBA/PC composites to a relatively weaker intensity with relatively lower peak of HRR (pk-HRR), compared with that of neat PC. And the pk-HRR of TDBA/PC composites reduced along with the increase of TDBA loadings. Especially, in the case of 10% TDBA/PC, its pk-HRR reduced by 29.2% than that of neat PC. Meanwhile, the early HRR within 100 s discloses that, the incorporation of TDBA shortened the time to ignition (TTI) of TDBA/PC composites. And roughly, the more TDBA was introduced in composite, the faster ignition of TDBA/PC composite happened. Besides, unlike the obvious single-peak HRR curve of neat PC, the fluctuant HRR platform around pk-HRR in TDBA/PC composite reveals that TDBA suppressed combustion of composite to a lower-intensity and roughly-stable combustion state. Hence, the effect of TDBA on HRR exposes that TDBA worked on the combustion of PC matrix starting from initial ignition to sufficient burning stages.
According to the mass loss curves of PC composites shown in Fig. 4, it can be observed that, compared with that of neat PC, the slope of the mass loss curves in TDBA/PC composites were all nearly equal to that of neat PC after ignition, although TDBA induced PC matrix to decompose in advance. It reveals that the mass loss rate of burning TDBA/PC composite was similar to that of burning neat PC, signifying that TDBA contributed less to the barrier effect of matrix residue on the volatiles release during combustion. Further, compared with that of neat PC, the much less residue retention of TDBA/PC composite even discloses that more decomposed volatiles were released into gaseous phase. Interestingly, compared with that of neat PC, the more mass of substances released from burning TDBA/PC composite resulted in lower total heat release (THR) instead. Especially, the THR of 10% TDBA/PC was obviously reduced by 18.58% than that of neat PC. These results reveals that TDBA suppressed the gaseous-phase combustion reaction of PC matrix.
In addition, the average effective heat of combustion (av-EHC) listed in Table 3 also verifies the gaseous-phase flame retardant effect of TDBA in TDBA/PC composite. Observably, the av-EHC of TDBA/PC composites decreased gradually with the increase of TDBA loadings. Namely, the addition of TDBA forced burning composite to proceed more incomplete combustion. This result strongly proves the gaseous-phase flame-retardant effect of TDBA. Meanwhile, the total smoke production (TSP) curves shown in Fig. 5 also afford evidence to the increased incomplete combustion in burning TDBA/PC composite. Compared with that of neat PC, the dramatically increased TSP of TDBA/PC composite reveals that the burning TDBA containing composite produced much more large-scale fragments which were finally released as smoke particles, rather than further pyrolyzed and oxidized. Further, the slope of TSP in TDBA/PC composites was gradually elevated with the increase of TDBA loadings, indicating the more addition of TDBA promoted faster and more smoke production. As for the obviously increased average COY (av-COY) and moderately reduced average CO2Y (av-CO2Y) in TDBA/PC composites, it demonstrates that the incorporation of TDBA also suppressed the final oxidative process of combustible pyrolysis products distinctly. Above results firmly verify that the gaseous-phase flame retardant action of TDBA in burning TDBA/PC composites dominantly suppressed the combustion behaviour of composite, and then endowed PC materials with higher flame retardancy.
Samples | Td,1% (°C) | Td,5% (°C) | Td,30% (°C) | Td,max (°C) | R450°C (wt%) | R539°C (wt%) | R700°C (wt%) | Tg (°C) |
---|---|---|---|---|---|---|---|---|
PC | 450 ± 2 | 507 ± 3 | 539 ± 4 | 545 ± 3 | 99.0 ± 0.1 | 70.0 ± 0.2 | 24.5 ± 0.3 | 148 ± 1.0 |
6% TDBA/PC | 380 ± 4 | 452 ± 4 | 519 ± 5 | 532 ± 4 | 95.2 ± 0.2 | 40.7 ± 0.2 | 22.0 ± 0.2 | 143 ± 0.5 |
8% TDBA/PC | 371 ± 3 | 432 ± 2 | 506 ± 3 | 525 ± 3 | 92.6 ± 0.2 | 32.5 ± 0.2 | 19.5 ± 0.2 | 141 ± 0.0 |
10% TDBA/PC | 356 ± 3 | 421 ± 3 | 500 ± 4 | 524 ± 5 | 90.3 ± 0.2 | 28.4 ± 0.2 | 17.6 ± 0.3 | 140 ± 0.5 |
TDBA | 308 ± 1 | 355 ± 1 | 439 ± 1 | 485 ± 1 | 63.6 ± 0.1 | 11.4 ± 0.1 | 10.3 ± 0.1 | 108 ± 1.0 |
Obviously, TDBA, neat PC, and TDBA/PC composites all show one-stage decomposition behavior. Compared with that of neat PC, the initial decomposition temperature (Td,1%) of TDBA/PC composites reduced gradually with the increase of TDBA loadings. Moreover, with further increasing temperature, this earlier-decomposition phenomenon was sustained although the decomposition temperature gap between neat PC and TDBA/PC composite was narrowed gradually, like Td,5% and Td,30%. Along this trend, in the aspect of the maximum decomposition rate temperature (Td,max), the difference between neat PC and TDBA/PC was obviously narrowed, and the content influence of TDBA was weaken greatly in TDBA/PC samples, especially between 8% TDBA/PC and 10% TDBA/PC. It suggested that, TDBA worked more mainly on the early decomposition of PC matrix. In the aspect of residue retention at certain temperature, it can be observed that the residue retention at 450 °C (R450°C) of TDBA/PC composites correspondingly reduced by 3.8 wt% to 8.7 wt% than that of neat PC, when TDBA loadings increased from 6 wt% to 10 wt%. With further increasing temperature to 539 °C, the difference in R539°C between neat PC and TDBA/PC composite was further enlarged to 29.3 wt% to 41.6 wt% along with TDBA loadings increasing from 6 wt% to 10 wt%. Combining the decomposition of TDBA alone, it can be observed that the mass loss of incorporated TDBA was far less than the mass loss gap between neat PC and TDBA/PC composite at both 450 °C and 539 °C. Through above parallel comparisons separately in temperature and residue retention, it can be concluded that TDBA induced PC matrix to decompose earlier and more. As for the final residue retention, the cases of R700°C in neat PC and TDBA/PC composites were well in accordance with the trend of those in cone calorimeter tests. Hence, it can be concluded that TDBA promoted the decomposition of PC matrix, resulting in more mass of substances released into gaseous phase.
The DSC evaluation was also carried out to explore the influence of TDBA on the thermal deformation property of PC material. As listed in Table 4, TDBA has a relatively lower glass transition temperature (Tg) around 108 °C, compared with that of neat PC. Fortunately, the incorporation of TDBA only slightly decreased the Tg of TDBA/PC composite by 5 °C to 8 °C with TDBA loadings increasing from 6 wt% to 10 wt%. It signifies that the addition of TDBA will not influence much on the upper-limit operating temperature of PC materials.
Fig. 7 FT-IR spectra of the evolved gases at different mass loss during TG procedure. (A) Neat PC; (B) 10% TDBA/PC. |
Fortunately, as shown in Fig. 7(B), the addition of TDBA dramatically suppressed the production of CH4 and carbonyl-containing substances from decomposing 10% TDBA/PC. And the suppressing effect on the production of CH4 was particularly obvious. Further, the emerging peaks at ∼1258 cm−1, ∼910 cm−1, and ∼748 cm−1 in Fig. 7(B) presented the existence of PO, P–O–Caromatic and ortho-disubstituted benzene, respectively.38,39 The appearance of these three peaks affords important evidences to the existence of phosphaphenanthrene segments in gaseous phase. Especially, the peaks of PO and P–O–Caromatic both belong to the key fragments of phosphaphenanthrene segments in flame retardant action. Also, the peak at ∼748 cm−1 still possibly responded to the pyrolysis products of the bi-substituted bisphenol-A segment in TDBA. Anyway, the FTIR results firmly verify the existence of the pyrolysis products from TDBA in gaseous phase, especially the clearly confirmed phosphaphenanthrene moieties. In addition, the remarkably enhanced peak of CaromaticCaromatic (∼1600 cm−1) in Fig. 7(B) also reveals that the incorporation of TDBA promoted decomposing PC matrix to form more aromatic fragments. Therefore, it can be concluded that, incorporated TDBA not only reduced the formation of extremely flammable CH4 and carbonyl-containing volatiles, but also forced PC matrix to decompose into more large-scale aromatic fragments, which were very likely to be released as smoke particles finally.
Fig. 8 (A) Gas chromatograms of neat PC and 10% TDBA/PC composite cracked at 500 °C. (B) MS spectrum of vinyl-substituted phosphaphenanthrene fragment from 10% TDBA/PC composite. |
As shown in Fig. 8(A), the pyrolysis of neat PC at 500 °C mainly produced two groups of fragments, shown as region (1) and (2). The fragments in region (1) belong to the semi-decomposed phenolic products from bisphenol-A segment while the fragments in region (2) belong to the initial-decomposed and undecomposed bisphenol-A fragments. As for the case of 10% TDBA/PC, its pyrolysis products can be divided into three parts. In region (1) and (2), the fragments of 10% TDBA/PC are almost the same as that in neat PC. Compared with the pyrolysis of neat PC, it can be concluded that the incorporation of TDBA inhibited PC matrix from pyrolyzing into semi- and initial-decomposed bisphenol-A fragments. Combined above discussions in cone calorimeter and TG-FTIR, these absent fragments should form large-scale aromatic particles, and be released as smoke finally. In region (3), the two moderate-intensity peaks represent methyl-substituted and vinyl-substituted phosphaphenanthrene fragments, respectively. With further pyrolysis, like the MS spectrum of vinyl-substituted phosphaphenanthrene shown in Fig. 8(B), series of PO free radicals (m/z = 215, 139, 63, and 47) should be produced and then be released from phosphaphenanthrene moieties. During combustion, these phosphaphenanthrene fragments, PO, and phenoxyl free radicals can quench indispensable active free radicals in combustion, and then suppress and even terminate the combustion chain reaction of burning materials. Above quenching effect from TDBA can exert outstanding gaseous-phase effect in suppressing the combustion of PC materials.
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