A novel oligomeric phosphorous–nitrogen-containing intumescent flame retardant poly (4,4-diaminodiphenylmethane-O-bicyclicpentaerythritol phosphate-phosphate) (PDBPP) is synthesized, and subsequently fullerene (C60)-decorated oligomeric intumescent flame retardant, C60-d-PDBPP, is fabricated via chemical grafting reaction and characterized. The grafting degree of C60 is as high as 70 wt%, and C60-d-PDBPP nanoparticles can homogeneously disperse in polypropylene matrix since the grafting process may prevent the aggregation of C60 particles. Upon incorporating C60-d-PDBPP, thermal oxidation degradation of polypropylene is considerably delayed. When the concentration of C60-d-PDBPP reached 2 wt%, the initial degradation temperature (T5: the temperature where 5wt% mass loss occurred) and maximum weight loss rate temperature (Tmax) display an increase of about 72 °C and 80 °C, respectively. Moreover, C60-d-PDBPP can remarkably reduce the peak heat release rate (PHRR) values of polypropylene, and consequently slow down the combustion process of nanocomposites. Additionally, to some extent it prolongs the time to ignition (tign) and time to peak heat release rate (tPHRR), all of which are very important parameters for evaluating the fire retardancy of a polymeric material.
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