Flame‐retardant properties and mechanisms of epoxy thermosets modified with two phosphorus‐containing phenolic amines

Two phosphorus‐containing phenolic amines, a 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO)‐based derivative (DAP) by covalently bonding DOPO and imine (SB) obtained from the condensation of p‐phenylenediamine with salicylaldehyde, and its analog (AP) via the addition reaction between diethyl phosphite and SB, were used to prepare flame‐retardant epoxy resins. The burning behaviors and dynamic mechanical properties of epoxy thermosets were studied by limited oxygen index (LOI) measurement, UL‐94 test, and dynamic mechanical analysis. The flame‐retardant mechanisms of modified thermosets were investigated by thermogravimetric analysis, Py‐GC/MS, Fourier transform infrared, SEM, elemental analysis, and laser Raman spectroscopy. The results revealed that epoxy thermoset modified with DAP displayed the blowing‐out effect during UL‐94 test. With the incorporation of 10 wt % DAP, the modified thermoset showed an LOI value of 36.1% and V‐0 rating in UL‐94 test. The flame‐retardant mechanism was ascribed to the quenching and diluting effect in the gas phase and the formation of phosphorus‐rich char layers in the condensed phase. However, the thermoset modified with 10 wt % AP only showed an LOI value of 25.7% and no rating in UL‐94 test, which was possibly ascribed to the mismatching of charring process with gas emission process during combustion. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43953.     

Flame retardancy and dielectric properties of dicyclopentadiene‐based benzoxazine cured with a phosphorus‐containing phenolic resin

A dicyclopentadiene‐based benzoxazine (DCPDBZ) was prepared and separately copolymerized with melamine–phenol formaldehyde novolac or phosphorus‐containing phenolic resin (phosphorus‐containing diphenol) at various molar ratios. Their curing behaviors were characterized by differential scanning calorimetry. The electrical properties of the cured resins were studied with a dielectric analyzer. The glass‐transition temperatures were measured by dynamic mechanical analysis. The thermal stability and flame retardancy were determined by thermogravimetric analysis and a UL‐94 vertical test. These data were compared with those of bisphenol A benzoxazine and 4,4′‐biphenol benzoxazine systems. The effects of the diphenol structure and cured composition on the dielectric properties, moisture resistance, glass‐transition temperature, thermal stability, and flame retardancy are discussed. The DCPDBZ copolymerized with phosphorus‐containing novolac exhibited better dielectric properties, moisture resistance, and flame retardancy than those of the melamine‐modified system. The flame retardancy of the cured benzoxazine/phosphorus‐containing phenolic resins increased with increasing phosphorus content. The results indicate that the bisphenol A and 4,4′‐biphenol systems with a phosphorus content of about 0.6% and the dicyclopentadiene system with a phosphorus content of about 0.8% could achieve a flame‐retardancy rating of UL‐94 V‐0. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Novel phosphorus‐based flame retardants containing 4‐tert‐butylcalix[4]arene: Preparation and application for the fire safety of epoxy resins

A novel flame retardant (FR) containing phosphorus and 4‐tert‐butylcalix[4]arene was synthesized and characterized. The FR combined with ammonium polyphosphate (APP) was then incorporated into epoxy resins (EPs) at different ratios. The flame retardancy, thermal stability, and smoke‐releasing properties were investigated. The limiting oxygen index was as high as 30.8% when the mass fraction ratio of the FR to APP was 1:2. The improved FR effect have been due to the combined FR effects between the FR and APP. The char residue content at 800 °C under a nitrogen atmosphere increased notably from 8.22% to 17.6% when the FR APP was incorporated into EP; this indicated an improvement in the thermooxidation resistance. From the cone test, we found that both the total heat‐release and peak heat‐release rate of the FR resins were reduced. Compared to the resins containing no FRs, the smoke‐production rate and total smoke‐production results indicate that the FR resins also exhibited good smoke‐suppression properties. Generally, the stable char layer of the FR APP–EP not only effectively prevented the release of combustion gases but also hindered the propagation of oxygen and heat into the interior substrate. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45105.     

Flame retardancy effects of phosphorus‐containing compounds and cationic photoinitiators on photopolymerized cycloaliphatic epoxy resins

This study presents a promising ultraviolet (UV)‐curable epoxy resin formulation with improved flame‐retardant properties. The formulation is based on the cycloaliphatic epoxide 3,4‐epoxycyclohexylmethyl‐3,4‐epoxycyclohexane carboxylate (ERL4221) and a novel silicon, phosphorous containing flame‐retardant additive. The additive, 1,3,5,7‐tetramethyl‐1,3,5,7‐tetra 2‐(6‐oxido‐6‐H‐dibenzo(c,e) (1,2)oxaphosphorin‐6‐yl) ethylcyclotetrasiloxane (DOPO‐SiD), was synthesized by the addition reaction of 1,3,5,7‐tetramethyl‐1,3,5,7‐tetravinylcyclotetrasiloxane (D₄Vi) with 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO). Formulations containing the cycloaliphatic epoxy resin ERL4221 and the flame‐retardant DOPO‐SiD additive were prepared in various concentrations and crosslinked by UV irradiation. The effects of DOPO‐SiD and photoinitiators, such as the cyclopentadienyl iron complex of carbazole (In‐Fe) and diphenyl‐(4‐(phenylthiol) phenyl) sulfonium hexafluorophosphate (In‐S), on the flame‐retardant properties and thermal stabilities of UV‐cured ERL4221/DOPO‐SiD composites were investigated with limiting oxygen index, UL‐94 vertical test, and thermogravimetric analysis, respectively. The results showed that DOPO‐SiD can increase the thermal stabilities of the ERL4221/DOPO‐SiD. The char yield was improved when DOPO‐SiD and In‐Fe were simultaneously used. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40011.     

Flame‐retarded polystyrene with phosphorus‐ and nitrogen‐containing oligomer: Preparation and thermal properties

A phosphorus‐ and nitrogen‐containing compound (2‐dimethylamino ethyl phenyl hydroxyethyl acrylate phosphate) and its oligomer (poly(2‐dimethylamino ethyl phenyl hydroxyethyl acrylate phosphate), PDPHP) were synthesized and characterized. The polystyrene (PS) composites with various amounts of PDPHP were prepared by melt blending. The thermal stability of the PDPHP and PS composites was investigated by thermogravimetric analysis. The flame retardancy of the composites was evaluated using microscale combustion calorimeter and limiting oxygen index test. A Fourier transform infrared (FTIR) spectroscopy coupled with a thermogravimetric analyzer was also used to study the gas phase from the degradation of PS composites. The char residues of the PS composites containing 30 wt % PDPHP were analyzed by FTIR and scanning electron microscopy. The results suggest that the incorporation of PDPHP into PS can evidently enhance the char formation and improve the flame retardancy of virgin PS. The compact and coherent char formed during degradation was attributed to the enhancement of char quality and flame retardance. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Polystyrene with trifluoromethyl units: Monomer reactivity ratios,thermal behavior,flammability, and thermal degradation kinetics

Chemical modification based on incorporation of flame retardants (FR) into the polymer backbone was used in order to reduce polystyrene flammability. 3‐(trifluoromethyl)styrene (StCF₃) and 3,5‐bis(trifluoromethyl)styrene (St(CF₃)₂) were applied as reactive FR. Copolymers were synthesized with different feed ratios and it gave series of copolymers with various amounts of StCF₃ and St(CF₃)₂ (5–50% mol/mol of St). Glass transition temperature (T_g) and thermal stability of obtained (co)polymers were determined from differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA), respectively. Kinetic parameters such as the thermal decomposition activation energy (E) and frequency factor (A) were estimated by Ozawa and Kissinger models. Pyrolysis combustion flow calorimeter (PCFC) was applied as a tool for assessing the flammability of the synthesized (co)polymers. Relative reactivity ratios were determined by applying the conventional linearization Jaacks method (r_St = 1.34_, r_StCF3 = 0.54), (r_St = 0.47_, r_St(CF3)2 = 0.13). The results suggest that incorporation of fluorinated styrenes into PSt enchance flame retardance. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42839.     

A phosphorus‐containing diamine for flame‐retardant,high‐functionality epoxy resins. I. Synthesis,reactivity, and thermal degradation properties

A phosphorus‐containing amine, bis(4‐aminophenoxy)phenyl phosphine oxide (BAPP), suitable for curing epoxy resins with improved fire performance was synthesized and characterized with Fourier transform infrared spectroscopy and nuclear magnetic resonance. The reactivity of the amino group was evaluated by differential scanning calorimetry of the epoxy–amine mixture and by proton nuclear magnetic resonance of the amino unit. With BAPP as a curing agent, a range of high‐functionality, aerospace epoxy resins were cured, and the dynamic kinetic parameters calculated from Kissinger's and Ozawa's models were compared with those from the more widely used amines. The thermal degradation properties of the phosphorus‐containing epoxy resins were studied by thermogravimetric analysis, the degradation activation energy was calculated, and a multistep thermal degradation process was observed. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 2093–2100, 2004     

Synthesis and characterization of phosphorus‐containing waterborne polyurethanes: Effects of the organophosphonate content on the flame retardancy,morphology, and film properties

A series of waterborne polyurethanes (WPUs) with different contents of reactive organophosphonate were well prepared. Their structures were characterized by Fourier transform infrared and ¹H‐NMR spectroscopy. Thermogravimetry and derivative thermogravimetry revealed that the WPU films containing phosphorus possessed lower onset and maximum degradation temperatures but higher char yields. Differential scanning calorimetry analysis suggested phase mixing of the hard and soft domains. The mechanical properties decreased with increasing amount of organophosphonate, whereas the limiting oxygen index results of the WPU films indicate that the flame retardancy was improved significantly by the incorporation of organophosphonate. The water uptake values of the organophosphonate‐containing WPU films were higher than those of the phosphorus‐free ones, whereas the static contact angles of the films indicated that the surface hydrophilic properties were not affected by segmenting in this phosphorus‐containing oligomer. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Synthesis and properties of novel phosphorus‐containing bismaleimide/epoxy resins

A novel soluble phosphorus‐containing bismaleimide (BMI) monomer, bis(3‐maleimidophenyl)phenylphosphine oxide (BMIPO), was synthesized by the imidization of bis(3‐aminophenyl) phenylphosphine oxide, in which its structural characterization was identified with ¹H‐NMR, ¹³C‐NMR, and Fourier transform infrared spectra. The BMIPO resin, with five‐membered imide rings and high phenyl density, was an excellent flame retardant with a high glass‐transition temperature (T_g), onset decomposition temperature, and limited oxygen index. In phosphorus‐containing BMI/epoxy/4,4′‐methylene dianiline (DDM)‐cured resins, homogeneous products were obtained from all proportions without phase separation. Because of the higher reactivity of BMIPO/DDM relative to that of 4,4′‐bismaleimidodiphenylmethane (BMIM)/DDM, the increase in the BMIPO/BMIM ratio in this blending resin increased the recrosslinking hazards of the postcuring stage and so lowered the T_g value and thermal stability. The thermal stability of the BMI/epoxy‐cured system was lower than that of the epoxy‐cured system because of the introduction of a phosphide group into BMIPO, whereas for the T_g value and flame retardancy, the former was significantly higher than the latter: the higher the BMIPO content in the blend, the higher the flame retardancy. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 2080–2089, 2002; DOI 10.1002/app.10607     

Thermal degradation and combustion behavior of intumescent flame‐retardant polypropylene with novel phosphorus‐based flame retardants

The objective of this study was to develop an environmentally friendly fire‐retardant polypropylene (PP) with significantly improved fire‐retardancy performance with a novel flame‐retardant (FR) system. The system was composed of ammonium polyphosphate (APP), melamine (MEL), and novel phosphorus‐based FRs. Because of the synergistic FR effects among the three FRs, the FR PP composites achieved a V‐0 classification, and the limiting oxygen index reached as high as 36.5%. In the cone calorimeter test, both the peak heat‐release rate (pHRR) and total heat release (THR) of the FR PP composites were remarkably reduced by the incorporation of the novel FR system. The FR mechanism of the MEL–APP–FR–PP composites was investigated through thermogravimetric analysis and char residue characterization, and the results reveal that the addition of MEL–APP–FRs promoted the formation of stable intumescent char layers. This led to the reduction of pHRR and THR and resulted in the improvement of the fire retardancy. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 45962.     

Preparation and properties of halogen‐free flame‐retarded phthalonitrile–epoxy blends

Halogen‐free flame‐retarded blends composed of 2,2‐bis[4‐(3,4‐dicyanophenoxy) phenyl] propane (BAPh) and epoxy resin E‐44 (EP) were successfully prepared with 4,4′‐diaminodiphenyl sulfone as a curing additive. The structure of the copolymers was characterized by Fourier transform infrared spectroscopy, which showed that epoxy groups, a phthalocyanine ring, and a triazine ring existed. The limiting oxygen index values were over 30, and the UL‐94 rating reached V‐0 for the 20 : 80 (w/w) BAPh/EP copolymers. Differential scanning calorimetry and dynamic rheological analysis were employed to study the curing reaction behaviors of the phthalonitrile/epoxy blends. Also, the gelation time was shortened to 3 min when the prepolymerization temperature was 190°C. Thermogravimetric analysis showed that the thermal decomposition of the phthalonitrile/epoxy copolymers significantly improved with increasing BAPh content. The flexible strength of the 20:80 copolymers reached 149.5 MPa, which enhanced by 40 MPa compared to pure EP. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Preparation and application of phosphorous‐containing bio‐polyols in polyurethane foams

A bio‐polyol phosphonate acting as the polyol component in the preparation of polyurethane foam was synthesized from the liquefaction product of bagasse by the halogenation of the liquefaction product followed by the Michaelis–Arbuzov rearrangement. The FT‐IR spectra showed that phosphorus‐containing groups were introduced into the polyol chain. The data of the viscosity and the hydroxyl number suggested that the bio‐polyol phosphonate would be a good polyol component in the preparation of polyurethane foam. The limiting oxygen index of polyurethane foam containing bio‐polyol phosphonate varied in the range of 24–28, while that of polyurethane foam without bio‐polyol phosphonate was 23, demonstrating that the introduction of the phosphorus‐containing group into the polymer helped to improve the flame retardancy. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40422.     

The synthesis and characterization of a novel phosphorus–nitrogen containing flame retardant and its application in epoxy resins

A novel, halogen‐free, phosphorus–nitrogen containing flame retardant 2[4‐(2,4,6‐Tris{4‐[(5,5‐dimethyl‐2‐oxo‐2λ⁵‐[1,3,2]dioxaphosphinan‐2‐yl)hydroxymethyl]phenoxy}‐(1,3,5)‐triazine (TNTP) was successfully synthesized in a three‐step process, and characterized by FTIR, NMR spectroscopy, mass spectra, and elemental analysis. A series of modified DGEBA epoxy resin with different loadings of TNTP were prepared and cured by 4,4‐diaminodiphenylsulfone (DDS). Thermal gravimetric analysis and vertical burning test (UL‐94) were used to evaluate the flame retardancy of TNTP on DGEBA epoxy resin. The results showed that TNTP had a great impact on flame retardancy. All modified thermosets by using TNTP exhibited higher T_g than pure DGEBA/DDS. The loading of TNTP at only 5.0 wt % could result in satisfied flame retardancy (UL‐94, V‐0) together with high char residue (27.3%) at 700°C. The addition of TNTP could dramatically enhance the flame retardancy of DGEBA epoxy resins, which was further confirmed by the analysis of the char residues by scanning electron microscopy and FTIR. Furthermore, no obviously negative effect was found on the Izod impact strength and flexural property of DGEBA epoxy resins when TNTP loading limited in 5.0 wt %. DGEBA/DDS containing 2.5 wt % TNTP could enhance Izod impact strength from 10.47 to 10.94 kJ m^?2, and showed no appreciable effect on the flexural property (85.20 MPa) comparing with pure DGEBA/DDS (87.03 MPa). Results indicated that TNTP as a phosphorus–nitrogen synergistic intumescent flame retardant could be used for DGEBA epoxy resin. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 41079.     

Phosphorus‐containing polyaryloxydiphenylsilanes with high flame retardance arising from a phosphorus–silicon synergistic effect

Polyaryloxydiphenylsilanes were prepared from phosphorus‐containing diols and diphenydichlorolsilane through solution polymerization. With a stoichiometric imbalance in feed monomers, the resulting polymers exhibited moderate melting points and good processing properties. The polymers prepared showed initial decomposition temperatures above 340 °C, excellent thermal stability, high char yields at 850 °C and very high limited oxygen index values of 56–59. The polymers' char yields and their (P + Si) contents showed linear relationships. © 2003 Society of Chemical Industry     

Synthesis,thermal and mechanical behavior of a silicon/phosphorus containing epoxy resin

A liquid silicon/phosphorus containing flame retardant (DOPO–TVS) was synthesized with 9,10‐dihydro‐9‐oxa‐10‐phosphapheanthrene‐10‐oxid (DOPO) and triethoxyvinylsilane (TVS). Meanwhile, a modified epoxy resin (IPTS–EP) was prepared by grafting isocyanate propyl triethoxysilane (IPTS) to the side chain of bisphenol A epoxy resin (EP) through radical polymerization. Finally, the flame retardant (DOPO–TVS) was incorporated into the modified epoxy resin (IPTS–EP) through sol–gel reaction between the ethyoxyl of the two intermediates to obtain the silicon/phosphorus containing epoxy resin. The molecular structures of DOPO–TVS, IPTS–EP and the final modified epoxy resin were confirmed by FTIR spectra and ¹H‐NMR, ³¹P‐NMR. Thermogravimetric analysis (TGA), differential scanning calorimetry, and limiting oxygen index were conducted to explore the thermal properties and flame retardancy of the synthesized epoxy resin. The thermal behavior and flame retardancy were improved. After heating to 600°C in a tube furnace, the char residue of the modified resin containing 10 wt % DOPO–TVS displayed more stable feature compared to that of pure EP, which was observed both by visual inspection and scanning electron microscope (SEM). Moreover, the mechanical performance testing results exhibited the modified epoxy resins possessed elevated tensile properties and fracture toughness which is supported by SEM observation of the tensile fracture section. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42788.     

Synthesis and characterization of water‐dispersed flame‐retardant polyurethane resin using phosphorus‐containing chain extender

In this research, a flame‐retardant water‐dispersed polyurethane resin was synthesized through incorporating phosphonate groups into the polyurethane structure in the chain‐extension step. A phosphorus‐containing reactive flame‐retardant compound was synthesized for this purpose. First, bis(4‐nitrophenyl)phenyl phosphine oxide was synthesized and then converted to bis(4‐amino phenyl)phenyl phosphine oxide (BAPPO) by reducing its nitro groups into amines. The obtained products were characterized by IR, ¹H‐NMR, and ³¹P‐NMR, and the thermal properties of the polymers were determined by DSC analysis. The BAPPO‐containing polyurethane showed physical properties that were almost similar to those of phosphorus‐free polyurethane and exhibited good flame resistance with a limiting oxygen index value of 27. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 91: 1314–1321, 2004     

Synthesis of a phosphorus‐ and nitrogen‐containing flame retardant and evaluation of its application in waterborne polyurethane

A phosphorus‐ and nitrogen‐containing intumescent flame retardant, pentaerythritol di‐N‐hydroxyethyl phosphamide (PDNP), was synthesized with phosphorus oxychloride, pentaerythritol, and ethanolamine as raw materials. Using the prepared PDNP as a chain extender, a series of flame‐retardant waterborne polyurethanes (WPU) were prepared, and their structures were characterized using NMR and Fourier transform infrared spectroscopy (FTIR). Additionally, the thermal properties and flame retardancy of WPU films were investigated by thermogravimetric analysis, limiting oxygen index (LOI) tests, cone calorimeter tests, and thermogravimetry‐FTIR. These results indicated that PDNP materials exhibit good char‐forming ability at high temperature and that PDNP‐modified waterborne polyurethane obtained an LOI value of 26.0% for a PDNP content of 9 wt %. Finally, the morphology and the element distributions of char residues of WPU were analyzed by scanning electron microscopy and energy dispersive spectrometry after combustion. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46093.     

Blended hybrids based on silsesquioxane–OH and epoxy resins

Blended hybrids based on silsesquioxane cyclohexyl trisilanol [STOH; i.e., (c‐C₆H₁₁)₇Si₇O₉(OH)₃] and epoxy resin 4,5‐epoxyhexyl‐1,2‐dimethyl acid diglycidyl ester (TDE‐85) were prepared with good compatibility of STOH up to 5 wt % with TDE‐85. The blended hybrid resins, with various STOH additions, were cured by 4,4′‐diaminodiphenylsulfone, and the curing reactions were investigated with differential scanning calorimetry. The incorporation of STOH increased the curing reaction of TDE‐85 for three active hydrogens existing in the STOH molecule. The storage moduli and glass‐transition temperatures of the cured hybrid resins were studied with dynamic mechanical analysis. The cured hybrids had higher storage moduli than the pure epoxy resins at lower temperatures and increased slightly even when the temperature was above the glass‐transition temperature. Two peaks appearing in tan δ curves indicated the block copolymer structure and two different glass‐transition temperatures of the cured hybrid resins. The thermal stability and flame retardancy of the cured hybrid resins were investigated with thermogravimetric analysis and limited oxygen index values, respectively. The results showed that introducing silsesquioxane–OH units into epoxy resins could improve the thermal stability and flame retardancy of the resins. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2007     

Synthesis of phosphorus‐ and phenyl‐based ROMP polymers and investigation of their effects on the thermomechanical and flammability properties of a polypropylene–IFR system

In this study, we present an approach for the synthesis of novel phosphorous‐ or phenyl‐ containing polymers, 2_phenyl, 3_phospho, and 2_phenyl‐co‐3_phospho, derived from ring‐opening metathesis polymerization (ROMP), to reduce the flammability of polypropylene (PP). The composites were processed by melt‐blending ROMP polymers and octaphenyl–polyhedral oligomeric silsesquioxane with PP/intumescent flame retardant (IFR) compounds at different compositions. The composites were characterized by limiting oxygen index (LOI), UL‐94, and mechanical tests as well as thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). The molecular structures of phosphorous‐ and phenyl‐containing polymers were proved by ¹H‐NMR, ¹³C‐NMR, and Fourier transform infrared spectroscopy. The online rheological measurements indicated that the addition of additives to the PP/IFR system increased the melt viscosity of the compounds regardless of the type. The DSC analysis showed that the addition of ROMP polymers to the PP/IFR system influenced the crystal perfection and degree of crystallization. TGA analysis of the composites revealed that the addition of ROMP polymers to PP/IFR compounds deteriorated the thermal stability as the amount of phosphorus increased in the matrix. Dynamic mechanical properties such as storage modulus (E′) and loss modulus (E″) of the composites were lowered by the addition of ROMP polymers. The LOI and UL‐94 rating of PP/IFR were enhanced by the addition of ROMP polymers. It was successfully demonstrated that the novel phosphorous‐ or phenyl‐containing polymers were highly potent additives in optimizing the flammability of PP composites. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 45998.     

Synthesis of a novel phosphorus‐containing dicyclopentadiene novolac hardener and its cured epoxy resin with improved thermal stability and flame retardancy

A novel phosphorus‐containing dicyclopentadiene novolac (DCPD‐DOPO) curing agent for epoxy resins, was prepared from 9,10‐dihydro‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO) and n‐butylated dicyclopentadiene phenolic resin (DCPD‐E). The chemical structure of the obtained DCPD‐DOPO was characterized with FTIR, ¹H NMR and ³¹P NMR, and its molecular weight was determined by gel permeation chromatography. The flame retardancy and thermal properties of diglycidyl ether bisphenol A (DGEBA) epoxy resin cured with DCPD‐DOPO or the mixture of DCPD‐DOPO and bisphenol A‐formaldehyde Novolac resin 720 (NPEH720) were studied by limiting oxygen index (LOI), UL 94 vertical test and cone calorimeter (CCT), and differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA), respectively. It is found that the DCPD‐DOPO cured epoxy resin possess a LOI value of 31.6% and achieves the UL 94 V‐0 rating, while its glass transition temperature (T_g) is a bit lower (133 °C). The T_g of epoxy resin cured by the mixture of DCPD‐DOPO and NPEH720 increases to 137 °C or above, and the UL 94 V‐0 rating can still be maintained although the LOI decreases slightly. The CCT test results demonstrated that the peak heat release rate and total heat release of the epoxy resin cured by the mixture of DCPD‐DOPO and NPEH720 decrease significantly compared with the values of the epoxy resin cured by NPEH720. Moreover, the curing reaction kinetics of the epoxy resin cured by DCPD‐DOPO, NPEH720 or their mixture was studied by DSC. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 44599.