Nanomorphology and fire behavior of polystyrene/organoclay nanocomposites containing brominated epoxy and antimony oxide

Organoclay nanocomposites were prepared by ultrasound‐assisted solution intercalation technique based on polystyrene containing brominated epoxy and a combination of brominated epoxy and antimony oxide. Aspects of nanomorphology and nanodispersion were investigated by X‐ray diffraction and transmission electron microscopy whereas flammability and reaction to fire were evaluated using limiting oxygen index, UL‐94, and mass loss calorimeter tests. Polystyrene/brominated‐epoxy‐blend‐based nanocomposites showed mixed intercalated–exfoliated nanomorphology where polymer‐intercalated crystallites predominantly exist in polystyrene matrix and exfoliated silicate layers reside on polystyrene/brominated epoxy phase boundaries and within brominated epoxy domains. Organoclay was found to impart a compatibilization effect on polystyrene and dispersed brominated epoxy, which facilitates uniform distribution of a fine flame‐retarding phase within the matrix. With the reduction of the rate at which decomposition products evolve into the gas phase, organoclay nanocomposites showed notable reductions in peak heat release rate and increases in limiting oxygen index. The gas‐phase hot radical entrapment by halogenated flame‐retardant system was coupled with the condensed‐phase physical action of nanodispersed organoclay, which increased the overall fire‐retardant effectiveness. Fire‐retardant mechanisms of nanocomposites based on polystyrene/brominated epoxy blends were attributed to nanoconfinement and tortuous pathway effects of organoclay rather than to carbonaceous char formation proposed earlier for polystyrene/organoclay systems without conventional flame retardants. Copyright © 2011 John Wiley & Sons, Ltd.     

Characterization of fire retardant polymer blends by temperature resolved in-source pyrolysis mass spectrometry

The characterization of fire retardant polymer blends by temperature resolved in-source pyrolysis mass spectrometry (PYMS) is demonstrated with a few examples. Electron impact (EI) and electron capture negative ionization (ECNI) were used to identify the thermal degradation products of polymer blends containing brominated fire retardants. PYMS (EI mode) offers an analytical instrument for a fast analysis of unknown mixtures of polymers and for the presence of fire retardant additives. Under electron impact conditions, in vacuo, low-molecular weight additives like fire retardants mainly evaporate from the polymer matrix. PYMS (EI mode) has been used for the characterization of addition polymers like polystyrene and acrylonitrile-butadiene-styrene copolymer, and for condensation polymers like the polyester poly(butylene terephthalate). Applying electron capture negative ionization, at low argon pressure in the ionization chamber, a more realistic pyrolysis situation is created because the premature loss of volatile additives is suppressed. The selectivity of ECNI for electron accepting groups like bromine makes it possible to study the influence of brominated compounds on the degradation processes in the melt. This is demonstrated by our studies on polystyrene and acrylonitrile-butadiene-styrene copolymer. High-molecular weight pyrolysis products in the m/z range of 1000 - 2000 are detected for p-bromopolystyrene and for a blend of high impact polystyrene with the fire retardant system decabromodiphenyl ether/antimony(III) oxide. In addition to the formation of antimony bromides shown in earlier studies, the emission of the synergist antimony(III) oxide as a dimeric cluster (Sb₄O₆) or as a reduced Sb₄ cluster is observed under PYMS conditions.     

Thermal decomposition of flame retardants: Mixtures of chlorinated polymers with Sb2O3 and (BiO)2CO3

The thermal decomposition products that evolve from mixtures of poly(vinyl chloride) (PVC), poly(vinylidene chloride) (PVC₂), and chlorinated paraffin (CP) with Sb₂O₃ and (BiO)₂CO₃, respectively, have been analyzed by a method of direct pyrolysis in the ion source of a mass spectrometer. This method allowed us to detect volatile products with masses as high as 226 (SbCl₃), 314 (BiCl₃), 484 (Sb₄), 580 (Sb₄O₆), and 836 (Bi₄). Except for SbCl₃, this is the first direct evidence of the presence of these species in the gas phase. The volatilization rate profiles of these species versus the pyrolysis temperature have been also determined. Our data confirm that the effectiveness of the title mixtures as flame-retardant agents depends on the transport of volatile metal products in the flame and provide direct evidence of the presence of metallic Sb and Bi below the polymer ignition temperatures.     

Hydrothermal decomposition of brominated epoxy resin in waste printed circuit boards

Brominated flame retardant (BFR), which containing in printed circuit boards (WPCBs), brings a series of environmental and health problems. Hydrothermal technology was applied to decompose brominated epoxy resin in WPCBs at subcritical or supercritical water conditions. The brominated epoxy resin was decomposed into oil and the environmental influence of BFR was eliminated. The experiment was carried out in a 5.7 ml tube reactor and heated by a salt-bath. The variation of degradation rate of brominated epoxy resin with reaction temperature, time and additives were studied. The compositions of liquid products were analyzed by gas chromatography-mass spectrometry (GC-MS). When reaction temperature exceeded 300 °C, retention time stayed over 30 min and alkaline additive existed, more than 80% brominated epoxy resin could be mainly decomposed into phenol, which can be used as chemical material. Two different hydrothermal decomposition pathways were discussed according to the characterization of products. The results indicated that brominated epoxy resin in WPCBs could be handled effectively by hydrothermal decomposition.     

Controlled pyrolysis of polyethylene/polypropylene/polystyrene mixed plastics with high impact polystyrene containing flame retardant: Effect of decabromo diphenylethane (DDE)

The pyrolysis of polyethylene(PE)/polypropylene(PP)/polystyrene(PS) mixed with high impact polystyrene (HIPS-Br) containing decabromo diphenylethane (DDE) as a brominated flame retardant with antimony trioxide as a synergist was performed under controlled temperature programmed pyrolysis (two steps) conditions to understand the decomposition behaviour and evolution of brominated hydrocarbons from flame-retardant additives. The liquid products were extensively analyzed by gas chromatographs equipped with FID, ECD, MSD, TCD, AED and FT-IR. The solid residue samples were analyzed by powder X-ray diffraction and combustion followed by ion-chromatography. The controlled pyrolysis of PE/PP/PS/HIPS-Br significantly affected the decomposition behaviour of HIPS-Br and subsequently the formation of decomposition products. GC/ECD analysis confirmed that the brominated hydrocarbons were concentrated in step 1 liquid products leaving less brominated hydrocarbons in the step 2 liquid products, similar to the decabromo diphenyl ether flame retardant containing mixed plastics. The yield of liquid products in step 1 from 3P/DDE-Sb(5) was 5 wt% and from 3P/DDE-Sb(0) was 2.4 wt%. The presence of antimony in the DDE containing plastics affected the yield of liquid, gas and residue products. ECD analysis showed that the presence of antimony increased the Br containing hydrocarbons and step 1 has 3-4 times higher brominated compounds than step 2 hydrocarbons in both the samples.     

Influence of flame retardant additives on the processing characteristics and physical properties of ABS

Antimony trioxide (Sb₂O₃) is a common additive in flame retardant formulations and a study has been made to determine the effects of adding different grades into ABS polymer either alone or with commercial brominated materials bis(Tribromophenoxy)ethane (BTBPE) or Tetrabromobisphenol A (TBBA). The results consider mechanical, microscopical and flame retardant properties, and the effects of different Sb₂O₃ grades with average particle sizes of 0.1μm, 0.52μm and 1.31μm. The Sb₂O₃ was added at 4wt% loadings and the bromines at 20wt% loadings. Additions of different grades of antimony trioxide showed that standard grades (0.52 and 1.31μm) had a detrimental effect on impact and flexural properties when added at a 4wt% loading. The use of a new sub‐micron particle size product (0.1μm) had little effect on impact properties and only a slight detrimental effect on the flexural modulus and flexural strength when added to the ABS. Additions of either of the two brominated materials also caused a large drop in impact properties when added at 20wt% loadings. The addition of TBBA BA‐59P into ABS caused an increase in both flexural modulus and flexural strength which was contrary to expectations. When formulated with 4wt% 1.31μm Sb₂O₃ these bromine containing compounds suffered a further reduction in impact energies. Using the 0.1μm material improved both impact and flexural properties but impact values were still below those of unfilled ABS. The addition of the 0.1μm grade resulted in improvements in fire resistance as measured by the UL‐94 properties.     

Catalytic destruction of brominated aromatic compounds studied in a catalyst microbed coupled to gas chromatography/mass spectrometry

The capability of solid porous catalysts has been studied for the destruction or modification of halogenated aromatic compounds contaminating the pyrolysis oil of recycled plastics from electronic waste. A fast and simple experimental procedure is carried out using a micropyrolyser coupled to GC-MS in such a way that catalyst microbed was placed in the sample tube of the pyrolyser. The pyrolysis products of polycarbonate blended with a frequently applied flame retardant tetrabromobisphenol A (TBBPA) and epoxy resin containing TBBPA monomer units have been analysed, and the brominated components were compared with the thermal decomposition products of TBBPA and its diallyl ether. When TBBPA vapour passes through molecular sieve 4A a slight debromination and a partial cleavage of bisphenol A into phenols occur. Over molecular sieves of larger pore size (13X and NaY zeolite) an important decrease of TBBPA amount is observed indicating effective trapping ability of these catalysts of basic character for brominated aromatic compounds. A total chemical modification of the vapour was achieved by Al-MCM-41 catalyst that split TBBPA into bromophenols. Analogous results were obtained by carrying out similar experiments on diallyl ether of TBBPA. Moreover, it was revealed that brominated bisphenol A compounds are modified essentially the same way, either evaporated or evolved from a polycarbonate blend or produced by pyrolysis from an epoxy resin.     

Kinetic studies of the decomposition of flame retardant containing high-impact polystyrene

The thermal decomposition of flame retardant free high-impact polystyrene (HIPS) and four HIPS samples containing brominated flame retardants has been studied using TGA at different heating rates between 2.5 and 10 K min⁻¹. Decabromodiphenyl ether (DPE) and decabromodibenzyl (DDB) were used as flame retardants, and two of the samples contained antimony trioxide (Sb₂O₃) synergist besides the brominated additives. The activation energies (E_A) and frequency factors (k₀) were calculated by the methods of Kissinger and Ozawa. A compensation effect was observed and used for the identification of changes in the degradation kinetics. In a third step, the kinetic model of the reaction was determined. Both Kissinger and Ozawa showed that the HIPS degraded with an E_A of 200 kJ mol⁻¹. The choice of the flame retardant had, however, little impact on the TGA plot. The addition of a flame retardant as well as the addition of Sb₂O₃ reduced the E_A. Fire retardant free HIPS degraded mainly by power-law kinetics, while the addition of a flame retardant caused the mechanism to change to a phase-boundary controlled mechanism after a weight loss of 80 wt%.     

A New Nano‐Structured Flame‐Retardant Poly(ethylene terephthalate)

A modified nano‐hydrotalcite was used as inorganic flame‐retardant fillers for poly(ethylene terephthalate) (PET) polymers. A flame‐retardant compound was obtained from layered hydrotalcite (LDH) dispersed in brominated polystyrene (PBS) solution and then solvent evaporation from the dissolved PBS samples. The compound of PBS/LDH was characterized by X‐ray diffraction (XRD), transmission electron microscopy (TEM) and thermogravimetric analysis (TGA) and was found to have high aspect ratio LDH dispersed in the PBS matrix. Flame‐retardant PET composite was prepared by melt‐compounding the flame‐retardant compound of PBS/LDH and PET. Improvement in the fire retardancy of the nano‐flame‐retardant PET composite obtained was found by measuring the oxygen index. The nanostructure of flame‐retardant PET composite was chirecterized by scanning electron microscopy (SEM) of flame‐retardant PET composite. The mechanical properties of the flame‐retardant PET nano‐composite were also characterized.     

Thermal degradation mechanism of flame retarded epoxy resins with a DOPO-substitued organophosphorus oligomer by TG-FTIR and DP-MS

A novel phosphorus-containing oligomeric flame retardant, poly(DOPO substituted hydroxyphenyl methanol pentaerythritol diphosphonate) (PDPDP) was synthesized and applied to flame retarded epoxy resins. The thermal degradation behaviors of flame retarded epoxy composites with PDPDP were investigated by thermogravimetric analysis (TGA), thermogravimetric analysis/infrared spectrometry (TG-FTIR) and direct pyrolysis-mass spectrometry (DP-MS) techniques. The identification of pyrolysis fragment ions provided insight into the flame retardant mechanism. The results showed that the mass loss rate of the EP/PDPDP composites was clearly lower than pure EP when the temperature was higher than 300 °C in air or nitrogen atmosphere. The results also suggested that the main decomposition fragment ions of the EP/PDPDP composite were H₂O, CO₂, CO, benzene, and phenol. The incorporation of PDPDP can reduce the release of combustible gas and induce the formation of char layer, hence the fire potential hazard was reduced.     

The formation of antimony oxychloride in flame retardant mixtures and its influence on flame retardant efficiency

Interaction of Sb₂O₃ with HCl vapour and chlorine-containing organic flame retardants in the presence and absence of polymers (polypropylene, polyethylene) has been studied at 473–773 K. It has been shown that SbOCl is formed in thermally degrading mixtures in the condensed phase. The influence of SbOCl formation on flame retardant efficiency is discussed.     

Thermogravimetric investigation ofwastes from electrical and electronic equipment (WEEE)

Two components of electronic wastes (sample A – a mixture of three types of printed circuit boards, sample B – a mixture of electronic junctions with metal wires) were investigated using thermogravimetric analysis (TG). Thermogravimetric and derivative thermogravimetric data (TG and DTG) give information on the thermal stability of A and B samples and allows finding the correct conditions for their degradation using pyrolysis in an experimental system, built on the laboratory scale for utilization of hazardous wastes. X-ray fluorescence measurements prove that brominated flame retardant is present in sample A, whilst chlorinated flame retardant is a probable component of sample B. Preliminary liquid chromatography of oil products obtained as a result of thermal waste degradation shows that the hydrocarbons released during pyrolysis could be used as a fuel.     

The influence of an N-alkoxy HALS on the decomposition of a brominated fire retardant in polypropylene

This work studies the effect of an N-alkoxy HALS on the thermal decomposition of a brominated phosphate ester fire retardant. We have monitored the fate of the fire retardant in the presence of the N-alkoxy HALS during thermal decomposition using TGA, FTIR, TD-GC-MS, NMR and ESR methods. We have shown that the two additives interact in the condensed phase at temperatures below the onset of polymer decomposition to produce 1,3-dibromo-2,2-bis(bromomethyl)-propane as the main decomposition product. It is believed that this molecule is the key to the fire retardant action of the brominated phosphate ester because it readily decomposes to the effective gas phase flame inhibiting agent, HBr.     

Study of flame retardance in brominated liquid polybutadienes

Bromination, carried out with either bromine or carbon tetrabromide, imparts good fire retardant characteristics to low molecular weight polybutadienes, independently of the method of bromination. The fire retardant action is due mainly to a condensed phase mechanism at a bromine content below 7%, whereas a gas phase mechanism is involved at higher bromine content. Synergism with Sb₂O₃ occurs only with polybutadienes brominated with carbon tetrabromide, apparently by a gas phase mechanism.     

Antimony oxide–PVC synergism: Laser pyrolysis studies of the interaction mechanism

Laser-probe pyrolysis is used to investigate the synergistic flame-retardancy effect observed for antimony oxide (Sb₂O₃)–PVC combinations. Molecular beam-mass analysis detection techniques permit direct sampling of the laser-vaporized species without the need for intermediate product collection stages. Laser pyrolysis of a PVC formulation containing 3 phr Sb₂O₃ provides the first direct evidence for the production of volatile SbCl₃ during thermal decomposition. Selective laser irradiation of PVC in the presence of unheated Sb₂O₃ in the sample cell reveals that HCl evolved from the polymer substrate rapidly reacts with Sb₂O₃(s) to form the volatile flame-retardant species SbCl₃. Similar results are observed for SbOCl(s). These reactions are distinct from those previously proposed, which involve the formation and subsequent thermal decomposition of intermediate solid-phase antimony oxychlorides, and demonstrate that the antimony compounds, rather than serving only as inert sources for SbCl₃, readily participate in direct chemical reactions with HCl. In addition to the composition of the reaction products, information is also obtained on their evolution characteristics from the sample cell.     

Miscibility behavior of di(ethyl-2 hexyl) phthalate in binary and ternary chlorinated polymer blends

The miscibility behavior of ternary blends made by the addition of di(ethyl-2 hexyl) phthalate (DOP) to a mixture of chlorinated polymers was investigated by differential scanning calorimetry. Two chlorinated polymer mixtures were selected: polyvinyl chloride (PVC) with a chlorinated polyethylene containing 48 wt% Cl (CPE48), and PVC with a chlorinated PVC containing 67 wt% Cl (CPVC67). Each binary DOP/chlorinated polymer pair is miscible whereas PVC/CPE48 and PVC/CPVC67 blends are immiscible. DOP/CPE48/PVC and DOP/PVC/CPVC67 ternary blends containing, respectively, more than 55 and 20% DOP exhibit a single glass transition temperature (T_g). The spinodal between the one-T_g zone and the two-T_g zone is symmetrical in the two cases. At high DOP concentrations, a quantitative analysis of the results leads to the conclusion of the presence of a true ternary phase. At low DOP concentrations where two T_gs are observed, the DOP is distributed equally between the two chlorinated polymers forming, in the DOP/CPE48/PVC case for instance, two binary DOP/CPE48 and DOP/PVC phases. The broad immiscibility zone observed in the DOP/CPE48/PVC ternary blend as compared to the DOP/PVC/CPVC67 blend appears to be mainly caused by the high molecular weight of CPE48, as compared with PVC and CPVC67. © 1994 John Wiley & Sons. Inc.     

磷酸酯双三聚氰胺盐阻燃环氧树脂的燃烧性能和阻燃机理

以季戊四醇、三氯氧磷、三聚氰胺为原料合成了[1-氧-4-亚甲基-2,6,7-三氧-1-磷杂双环(2,2,2)辛烷]磷酸酯双三聚氰胺盐阻燃剂,将该阻燃剂加入到环氧树脂中制成阻燃环氧树脂。用TG、SEM、EDS和FT-IR进行表征,并采用极限氧指数法和垂直燃烧法测试材料的燃烧性能,结果表明,极限氧指数和垂直燃烧性能随阻燃剂含量的增加而提高,当阻燃剂含量达到30%时,氧指数达到36,垂直燃烧性能达到V-0级;阻燃剂对材料的成炭量影响不大,但改变了炭层的组成和物理性质,燃烧过程中形成的含有P、O、N的粘性高聚物将炭层连接在一起,起到了隔热、隔氧作用,发挥了凝聚相阻燃作用。此外,阻燃环氧树脂在燃烧过程中有NH3等不燃气体逸出,有效地稀释了气相中的氧气浓度,发挥了气相阻燃作用,对材料的阻燃有协同作用。     

Comparison of thermal degradation products from real municipal waste plastic and model mixed plastics

The thermal degradation of real municipal waste plastic (MWP) obtained from Sapporo, Japan and model mixed plastics was carried out at 430 °C in atmospheric pressure by batch operation. The chlorinated hydrocarbons found in PE/PP/PS/PVC [poly(ethylene)/poly(propylene)/poly(styrene)/poly(vinyl chloride)] degradation liquid products were also observed in PE/PP/PS/PVC/PET (poly(ethylene terephalate)) and MWP degradation liquid products. The presence of PET in MWP produced the additional chlorinated hydrocarbons, which are similar to the chlorinated hydrocarbons observed during the PE/PP/PS/PVC/PET degradation liquid products. In addition, the presence of PET facilitated the formation of more organic chlorine content in liquid products and drastic decrease in the formation of inorganic chlorine content.     

Miscible blends of amorphous polymers

Thirty-five polymethacrylate/chlorinated polymer blends were investigated by differential scanning calorimetry. Poly(ethyl), poly(n-propyl), poly(n-butyl), and poly(n-amyl methacrylate)s were found to be miscible with poly(vinyl chloride) (PVC), chlorinated PVC, and Saran, but immiscible with a chlorinated polyethylene containing 48% chlorine. Poly(methyl) (PMMA), poly(n-hexyl) (PHMA), and poly(n-lauryl methacrylate)s were found to be immiscible with the same chlorinated polymers, except the PMMA/PVC, PMMA/Saran, and PHMA/Saran blends, which were miscible. A high chlorine content of the chlorinated polymer and an optimum CH₂/COO ratio of the polymethacrylate are required to obtain miscibility. However, poly(methyl), poly(ethyl), poly(n-butyl), and poly(n-octadecyl acrylate)s were found to be immiscible with the same chlorinated polymers, except with Saran, indicating a much greater miscibility of the polymethacrylates with the chlorinated polymers as compared with the polyacrylates.     

Kinetics study of thermal decomposition of epoxy resins containing flame retardant components

Hyperbranched polyphosphate ester (HPPE) and phenolic melamine (PM) were blended in different ratios with a commercial epoxy resin to obtain a series of flame retardant resins. The thermal decomposition mechanism of their cured products in air was studied by thermogravimetric analysis and in situ Fourier-transform infrared spectroscopy. The degradation behaviours of epoxy resins containing various flame retardant components were found to be greatly changed. The incorporation of phosphorus and nitrogen compounds improved the thermal stability at elevated temperature. The kinetics of thermal decomposition was evaluated by Kissinger method, Flynn-Wall-Ozawa method and Horowitz-Metzger method. The results showed that the activation energy at lower degree of the degradation decreased by the incorporation of flame retardant components, while increased at higher degree of the degradation.