Nana Tiana,
Jiang Gongab,
Xin Wena,
Kun Yaoab and
Tao Tang*a
aState Key Laboratory of Polymer Physics and Chemistry, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022, China. E-mail: ttang@ciac.ac.cn; Fax: +86 (0)431 85262827; Tel: +86 (0)431 85262004
bUniversity of Chinese Academy of Sciences, Beijing 100049, China
First published on 3rd April 2014
A novel organophosphorus, poly(4,4-dihydroxy-1-methyl-ethyl diphenol-o-bicyclic pentaerythritol phosphatephosphate) (PCPBO), was synthesized and characterized by FTIR, 1H NMR and 31P NMR. The flame retardancy and thermal stability of epoxy resin with different PCPBO loadings were investigated using the limited oxygen index (LOI), vertical burning test, cone calorimeter test and thermogravimetric analysis. The results showed that the incorporation of PCPBO into epoxy resin (EP) significantly improved its flame retardancy and thermal stability. The reduction of the peak heat release rate, total heat release and the increased char yield at high temperature further confirmed the improvement of the flame retardancy. FT-IR at different temperatures and the scanning electron microscopy of residual char revealed that the addition of PCPBO could induce the formation of an intumescent char layer, which retarded the degradation and combustion process of EP.
In the past decades, halogen-containing compounds are widely used as additive to improve the flame retardancy of epoxy resin. Nevertheless, the main problem is the generation of a large amount of toxic and corrosive gases from these halogen-containing flame retardants during combustion, which leads to environmental pollution.6,7 Consequently, many researchers pay more attention to exploit the halogen-free flame retardants for epoxy resin. Among the halogen-free systems, epoxy resin modified by phosphorus-containing compounds is considered as efficient method due to its notable flame retardant efficiency.8–10
In the recent years, 2,6,7-trioxa-1-phosphabicyclo[2,2,2]octane-4-methanol (PEPA) and its derivatives, as a novel kind of phosphorous-containing flame retardants, have attracted more attention because of their high reactivity and good charring.11–14 However, these compounds reported are mostly low molecular weight, which exist many shortcomings such as migration, leaching and poor compatibility with polymer matrix. Therefore, oligomeric and polymeric flame retardants with more aromatic structure have been proposed to deal with this problem. The polymeric flame retardant modified by PEPA is seldom reported up to now.
In order to improve the flame retardancy of epoxy resins, we synthesized a novel organophosphorus oligomer which contained aryl and caged bicyclic phosphate functional groups at the same time. The chemical structure of this compound was characterized by Fourier transform infrared (FT-IR) and nuclear magnetic resonance (NMR). The thermal degradation behaviors and the flame retardancy were investigated by thermogravimetric analysis (TGA) and cone calorimeter test, respectively.
| Sample | PCPBO content (wt%) | Flame retardancy | |
|---|---|---|---|
| LOI | UL-94 | ||
| EP | 0 | 22.5 | Fail |
| EP1 | 5 | 27.3 | Fail |
| EP2 | 10 | 28.8 | Fail |
| EP3 | 15 | 30.3 | V-1 |
| EP4 | 20 | 31.2 | V-0 |
Samples were thermally treated at a heating rate of 10 °C min−1 in a muffle furnace in air. The solid residues were obtained when heated to the designed temperature, and maintained at each temperature for 10 min. Then the residues were mixed with KBr powder and pressed into discs for FT-IR analysis.
The limiting oxygen index (LOI) values were measured on an HC–2C oxygen index meter (Jingning Analysis Instrument Company, China) with sheet dimensions of 130 mm × 6.5 mm × 3 mm according to the ASTM D2863-97 standard. The vertical burning tests were tested according to the UL-94 test standard (ASTM D3801, 2010) with the test specimen was 130 × 13 × 3 mm3.
Differential scanning calorimeter (DSC) was carried out under a nitrogen atmosphere by means of METTLER TOLEDO-DSC1 analyzer from 25 to 200 °C at a heating rate of 10 °C min−1. The nitrogen flowrate was 100 mL min−1.
Thermogravimetric analysis (TGA) was carried out with a Q600 thermal analyzer (TA Co., New Castle, USA) from ambient temperature to 800 °C at a heating rate of 10 °C min−1 under both air and nitrogen atmosphere with a flowing rate of 100 mL min−1. The char morphology was observed by means of field emission scanning electron microscopy (FE-SEM, XL303SEM).
Cone calorimeter tests were performed using an FTT, UK device according to ISO 5660 at an incident flux of 50 kW m−2, and the size of specimens was 100 mm × 100 mm × 6.0 mm; all samples were burned in triplicate and the data were the average of three replicated tests.
The morphology of the residual chars obtained was examined by means of field emission scanning electron microscopy (XL303SEM). The surface of residual chars was sputter-coated with gold layer before examination.
X-ray photoelectron spectroscopy (XPS) spectra of the char residue was recorded with a VG ESCALAB MK II spectrometer using an Al Kα exciting radiation from an X-ray source operated at 10.0 kV and 10 mA.
C in benzene ring. The absorption bands for P
O and P–O–C stretching vibration appear at 1224 cm−1 and 1034 cm−1, respectively. The absorption at 839 cm−1 is attributed to the skeleton vibration of caged phosphates.
Fig. 2 illustrates the 1H NMR spectra of PCPBO with the assignments of all the protons. The multiplet between 6.64 and 7.25 ppm (c and d) is assigned to the protons of benzene ring. The doublets at 4.60 (a) and 4.15 ppm (b) correspond to CH2 protons from the caged bicyclic phosphate and adjacent to the caged ring, respectively. The CH3 protons in PCPBO appear from 1.52 and 1.63 ppm (e). The structure of PCPBO was also confirmed by 31P NMR (Fig. 3). Two sharp signals are observed because of the molecular structure containing two different chemical shifts of phosphorus atoms. The peak of phosphorus (a) adjacent to bisphenol A appears at −7.71 ppm. The peak at −11.77 ppm corresponds to the phosphorus (b) of the caged bicyclic phosphates. From the above analysis, it is confirmed that the target product has been synthesized successfully.
The flammability performance and the experimental data are presented in Fig. 4 and Table 2, respectively. It can be clearly seen from Fig. 4(a) that pure EP burns very fast after ignition and a sharp HRR peak appears with PHRR as high as 1160.9 kW m−2. However, the addition of PCPBO leads to reduction in PHRR and the sample with 20 wt% PCPBO content exhibits the lowest PHRR value (337.1 kW m−2), which is reduced by 71% compared to that of EP. It can be found that tign for EP/PCPBO systems is lower than that for EP (see Table 2) and much more lower with the increase of PCPBO incorporation because of the lower initial degradation temperature for PCPBO than that for EP. A similar phenomenon was observed by Song et al.17 Moreover, the tPHRR values for EP/PCPBO systems are postponed from 210 to 392 s with increasing content of PCPBO in EP. In the case of EP with 20 wt% PCPBO, its tPHRR is 182 s longer than that of EP, indicating that PCPBO is an excellent flame retardant. It is worth noticing that there are two obvious peaks of the HRR curve of EP–PCPBO mixtures, which is a typical character of intumescent systems.18 The first peak corresponds to the ignition and to the flame spread on the surface of the materials and then to protection via the intumescent coating when the HRR values become constant. The material is protected by the intumescent char in this time zone. The second peak means the destruction of the intumescent structure and the formation of a carbonaceous residue.
| Sample | tign (s) | PHRR (kW m−2) | AHRR (kW m−2) | tPHRR (s) | THR (MJ m−2) |
|---|---|---|---|---|---|
| a Residual char%: mass percentage left when testing finished. | |||||
| EP | 76 | 1160.9 | 328.8 | 210 | 135.0 |
| EP1 | 65 | 882.8 | 306.6 | 230 | 132.1 |
| EP2 | 61 | 460.5 | 198.6 | 270 | 122.3 |
| EP3 | 44 | 375.4 | 177.4 | 305 | 119.8 |
| EP4 | 31 | 337.1 | 142.9 | 392 | 117.3 |
Fig. 4(b) presents THR curves for EP and its mixture. The slope of THR curve is assumed as representing the fire spread rate.19 It can be found that the flame spread for EP–PCPBO mixtures decreases with the increase of PCPBO content in comparison with pure EP during the whole testing process, and the value of THR for EP4 is 117.3 MJ m−2, which is reduced by 13.1% comparing with that of pure EP. Based on the results obtained from cone calorimetry, a conclusion can be drawn that PCPBO is an effective flame retardant for EP because it could reduce significantly the HRR for EP during combustion.
Fig. 5 presents the digital photographs for the residues of EP and EP–PCPBO mixtures after LOI test (up) and cone calorimeter measurements (down). It is clearly seen from Fig. 5(a) and (a′) that the residue of pure EP is not obviously expanded at the end of combustion. However, as for EP–PCPBO mixtures, the more the content of PCPBO, the more obvious the expansion is. As shown in Fig. 5(e′) for EP/20 wt% PCPBO (EP4), it can be observed that the residual char after cone calorimeter test increases significantly. Moreover, the visual observation of the residues can be maintained and looks like a hill.
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| Fig. 5 Photographs of the char residues after LOI (a: EP; b: EP1; c: EP2; d: EP3; e: EP4) and cone calorimeter tests (a′: EP; b′: EP1; c′: EP2; d′: EP3; e′: EP4). | ||
SEM is widely used as a tool to observe the morphology of the residual chars. Fig. 6 displays the SEM images of the surface residual chars for different samples after LOI test. As for pure EP, the surface of residual char appears uneven. Meanwhile, the obvious cracks can be observed, and it is unable to swell and form an intumescent char layer. However, with the increase of PCPBO content, the surface of residual char becomes more and more compact and continuous. As can be seen from Fig. 6 (EP4), the surface of residue is tight, indicating the formation of a dense and cohesive char layer structure and against volatiles diffusion during the burning process. Thus, it can be found that the morphologies of residual char become compact with the increase of PCPBO content. This phenomenon coincides well with the results of the LOI and UL-94 test.
| Sample | Tg (°C) | Air | Nitrogen | ||||
|---|---|---|---|---|---|---|---|
| T5% (°C) | Tmax (°C) | Chara | T5% (°C) | Tmax (°C) | Chara | ||
| a Char yield at 700 °C. | |||||||
| EP | 133 | 327 | 349, 536 | 0.1 | 340 | 367 | 7.9 |
| PCPBO | — | 228 | 306, 591 | 17.7 | 234 | 354, 469 | 25.6 |
| EP1 | 115 | 270 | 287, 520 | 1.3 | 304 | 355 | 11.7 |
| EP2 | 110 | 256 | 292, 510 | 4.1 | 291 | 358 | 12.8 |
| EP3 | 98 | 253 | 298, 510 | 4.8 | 284 | 360 | 15.9 |
| EP4 | 88 | 227 | 299, 508 | 7.2 | 267 | 362 | 16.6 |
In order to investigate the effect of PCPBO on the thermal stability of epoxy resin, TGA was measured and analyzed. Fig. 8 illustrates TG and DTG curves of EP with different contents of PCPBO under air atmosphere, respectively. The temperature at which the weight loss is about 5% is determined as the initial decomposition temperature. T5%, the temperature at maximum rate of weight loss (Tmax), and the percentage of char yield at 700 °C are summarized in Table 3.
As can be observed in Fig. 8, the pure EP starts to decompose at 327 °C and the thermal oxidative degradation process mainly has two stages. The first stage is in the temperature range of 300–400 °C corresponding to a strong DTG peak at 349 °C. The second stage is in the temperature ranges of 400–550 °C corresponding to Tmax of 536 °C. As for EP–PCPBO mixtures, the thermal oxidative degradation process of all the samples have the similar two stages as the pure EP. However, T5% decreases when PCPBO content increases, which is probably due to the decomposition of P–C bonds which have lower thermal stability than C–C bonds.22 In addition, the char yield for EP4 (with 20 wt%) increases to 7.2%.
From Fig. 9, the thermal degradation process under N2 atmosphere is different from that under air. The thermal degradation process of all samples has only one stage. When the PCPBO content increases, T5% decreases, showing a similar trend to the one mentioned above. It can be seen that the weight loss rate of the phosphorus-containing resin is significantly lower than that of the phosphorus-free resin under both air (Fig. 8(b)) and inert (Fig. 9(b)) atmosphere. This behavior is in accordance with the mechanism of improved flame retardancy via phosphorus modification:23 the PCPBO can catalyze the polymer matrix to form an insulating protective layer, which reduces the weight loss rate, increases the thermal stability at higher temperatures, and improves the flame retardancy.
C stretching vibration (1610, 1509, and 1460 cm−1) and alkyl–aryl ether bonds (1240 and 1035 cm−1) decrease remarkably, suggesting that the main decomposition happens at this stage. This is consistent with the TGA results. It is worth noting that the aromatic ring C
C stretching vibration at 1610 and 1509 cm−1 disappear, and a new broader peak at 1595 cm−1 appears, indicating that the formation of polyaromatic carbons by crosslinking.27 Furthermore, for the residue above 350 °C, their FTIR spectra are similar, indicating the chemical structure of residue became stable with consumption of this residue through the thermal oxidation process.
The FT-IR spectra of the EP4 at different degradation temperatures are shown in Fig. 11. It can be found that the relative intensities of CH3 stretching vibration at 2964–2870 cm−1 and CH3 deformation vibration at 1363 cm−1 decrease gradually from 200 to 330 °C and disappear completely at above 350 °C. Meanwhile, the peak at 1036 cm−1 assigned to P–O–C bond disappears completely at 300 °C, indicating that P–O–C bond in PCPBO is not stable when heated. Moreover, the C
C stretching vibration of polyaromatic carbons at 1594 cm−1 and some CAr–H deformation vibration at 757 cm−1 could be detected at high temperature region, implying the formation of polyaromatic structures.24 In addition, the new broad peak at 1085 cm−1 appears, which means more C–O structure exist in the residue.28
Based on the experimental results and the relevant literature,12,29 a possible route of the degradation process of PCPBO is illustrated in Fig. 12. It can be found that the two main decomposition products, including phosphate groups and some aromatic molecules, are produced in the degradation process. According to our previous research,30 phosphate groups will further degrade into phosphoric acid and pentaerythriol. The phosphoric acid not only catalyzes the dehydration and charring of PER, but also produces a pyrophosphoric structure in the form of P–O–P in the condensed phase.12 In addition, after isomerization and cyclization, pentaerythriol will form the stable char residue layer, which could prevent the heat transfer and protect the underlying materials from further burning and pyrolysis. Moreover, through a series of chemical reactions, including scission of main chain, crosslinking and thermal oxidation, the aromatic molecules eventually exist in form of polyaromatic carbons.
O in phosphate or carbonyl groups and the peak centered at 533.1 eV corresponds to –O– in C–O–C, C–O–P and/or C–OH groups. For the N1s spectra, the peak at 400.1 eV corresponds to the formation of some oxidized nitrogen compounds. The single peak at 133.1 eV in P2p spectrum can be assigned to the pyrophosphate and/or polyphosphate.32,33 Furthermore, it can be seen from Table 4 that the atomic concentrations of phosphorus and oxygen increase after addition of PCPBO, because of the crosslinking of phosphate and phosphate ester and the thermal oxidation of the aromatic molecules at high temperature, which leads to remaining the majority of phosphorus and oxygen in condensed phase. This phenomenon is coincided with the results of FTIR analysis.
| Sample | Binding energy (eV) | Atom (%) |
|---|---|---|
| EP | ||
| C1s | 284.6, 286.0, 288.6 | 87.48 |
| O1s | 531.8, 533.1 | 10.89 |
| N1s | 400.1 | 1.61 |
| P2p | 133.1 | 0.02 |
| EP4 | ||
| C1s | 284.6, 286.0, 288.6 | 80.74 |
| O1s | 531.8, 532.9 | 16.91 |
| N1s | 400.1 | 1.49 |
| P2p | 133.1 | 0.86 |
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