Flame Retardancy Index (FRI) for Polymer Materials Ranking.

In 2019, we introduced Flame Retardancy Index (FRI) as a universal dimensionless index for the classification of flame-retardant polymer materials (Polymers, 2019, 11(3), 407). FRI simply takes the peak of Heat Release Rate (pHRR), Total Heat Release (THR), and Time-To-Ignition (ti) from cone calorimetry data and quantifies the flame retardancy performance of polymer composites with respect to the blank polymer (the reference sample) on a logarithmic scale, as of Poor (FRI ˂ 100), Good (100 ≤ FRI ˂ 101), or Excellent (FRI ≥ 101). Although initially applied to categorize thermoplastic composites, the versatility of FRI was later verified upon analyzing several sets of data collected from investigations/reports on thermoset composites. Over four years from the time FRI was introduced, we have adequate proof of FRI reliability for polymer materials ranking in terms of flame retardancy performance. Since the mission of FRI was to roughly classify flame-retardant polymer materials, its simplicity of usage and fast performance quantification were highly valued. Herein, we answered the question "does inclusion of additional cone calorimetry parameters, e.g., the time to pHRR (tp), affect the predictability of FRI?". In this regard, we defined new variants to evaluate classification capability and variation interval of FRI. We also defined the Flammability Index (FI) based on Pyrolysis Combustion Flow Calorimetry (PCFC) data to invite specialists for analysis of the relationship between the FRI and FI, which may deepen our understanding of the flame retardancy mechanisms of the condensed and gas phases.

Facile preparation of flame-retardant cellulose composite with biodegradable and water resistant properties for electronic device applications.

The aim of the present study is to produce flexible, flame-retardant, water-resistant and biodegradable composite materials. The ultimate goal of this research is to develop simple processes for the production of bio-based materials capable of replacing non-degradable substrates in printed circuit board. Cellulose was chosen as a renewable resource, and dissolved in 1-ethyl-3-methylimidazolium acetate ionic liquid to prepare a cellulosic continuous film. Since flame retardancy is an important criterion for electronic device applications and cellulose is naturally flammable, we incorporated ammonium polyphosphate (APP) as a flame-retardant filler to increase the flame retardancy of the produced materials. The developed material achieved a UL-94 HB rating in the flammability test, while the cellulose sample without APP failed the test. Two hydrophobic agents, ethyl 2-cyanoacrylate and trichloro(octadecyl)silane were applied by a simple dip-coating technique to impart hydrophobicity to the cellulose-APP composites. Dynamic mechanical analysis indicated that the mechanical properties of the cellulosic materials were not significantly affected by the addition of APP or the hydrophobic agents. Moreover, the biodegradability of the cellulosic materials containing APP increased owing to the presence of the cellulase enzyme. The hydrophobic coating slightly decreased the biodegradability of cellulose-APP, but it was still higher than that of pure cellulose film.

The Effect of Combined Atmospheric Plasma/UV Treatments on Improving the Durability of Flame Retardants Applied to Cotton.

Application of a combined atmospheric plasma/UV laser to cotton fabrics impregnated with selected non-durable flame retardants (FRs) has shown evidence of covalent grafting of the latter species on to cotton fibre surfaces. As a result, an increase in their durability to water-soaking for 30 min at 40 °C has been recorded. Based on previous research plasma gases comprising Ar80%/CO220% or N280%/O220% were used to pre-expose cotton fabric prior to or after FR impregnation to promote the formation of radical species and increased −COOH groups on surface cellulosic chains, which would encourage formation of FR-cellulose bonds. Analysis by scanning electron microscopy (SEM/EDX), X-ray photoelectron spectroscopy (XPS) and thermal analysis (TGA) suggested that organophosphorus- and nitrogen- containing flame retarding species in the presence of the silicon-containing molecules such as 3-aminopropyltriethoxy silane (APTS) resulted in formation of FR-S-O-cellulose links, which gave rise to post-water-soaking FR retentions > 10%. Similarly, the organophosphorus FR, diethyl N, N bis (2-hydroxyethyl) aminomethylphosphonate (DBAP), after plasma/UV exposure produced similar percentage retention values possibly via (PO).O.cellulose bond formation, While none of the plasmas/UV-treated, FR-impregnated fabrics showed self-extinction behaviour, although burning rates reduced and significant char formation was evident, it has been shown that FR durability may be increased using plasma/UV treatments.

Thermal Stability, Flammability and Mechanical Performances of Unsaturated Polyester-Melamine Resin Blends and of Glass Fibre-Reinforced Composites Based on Them.

A novel blend of unsaturated polyester (UP) resin with an inherently flame-retardant and char-forming melamine formaldehyde (MF) resin has been prepared with the aim of reducing the flammability of the former. MF resin, sourced as a spray-dried resin, was dissolved in diethyleneglycol solvent; the dissolved resin and the UP-MF blend were autocured by heating under conditions normally used for curing UP, i.e., room temperature for 24 h and post-curing at 80 °C for 12-24 h. The cured UP-MF blends, although heterogeneous in nature, were rigid materials having fire performances superior to those of the cured UP alone. The blends also burned, but with a much reduced smoke output compared with that from UP. Although the heterogeneity of the blends helped in improving the fire performances of the blends in terms of the MF domains forming a semi-protective char, acting as thermal barriers for the adjoining UP domains, and hence reducing their thermal degradation, the mechanical properties of composites based on them were impaired. Nevertheless, whilst UP/MF blends may not be suitable for use as matrices in glass-reinforced composites in load-bearing applications, they may lend themselves to applications as fire-retardant gel coats, especially in view of their low-smoke, char-forming attributes.

Construction of hydrophobic fire retardant coating on cotton fabric using a layer-by-layer spray coating method.

Multifunctional cotton fabric was prepared through a two-step layer-by-layer spray coating method, where the first layer of the coating comprising chitosan and ammonium phytate provided fire retardancy, and the second one with PDMS-ZnO composite imparted hydrophobicity to the fabric. A molecular dynamics (MD) simulation study was carried out to calculate interfacial adhesion of different components of the coating, based on which the sequencing of the coating layers was determined and used to prepare coated samples. The coated fabric demonstrated a significant improvement in fire retardancy through an increase in LOI from 18 % in control to 30 %, a reduction in char length from 30 cm to 7 cm, and a decrease in peak and total heat release rate values by 75 % and 33 %, respectively. The hydrophobicity of coated fabric was tested via water drop test where coated sample maintained a contact angle of 148° for up to 120 s, while the control sample showed 0°.

Investigation and Optimization of Vacuum Plasma Treatment of PA66 Fabric for Reduced Fire Retardant Consumption.

Flame retardant (FR) textiles were obtained by surface treatments of polyamide 66 fabrics with microwave (MW) plasma technology in order to reduce the amount of FR involved in the fabric finishing process. More specifically, MW vacuum plasma was employed for polymer surface activation by using a helium/oxygen (He/O2) gas mixture, evaluating the effect of different treatment parameters on the affinity toward thiourea impregnation. Surface fabric modification was investigated both in terms of uniformity and increased thiourea absorption by infrared spectroscopy, wicking properties, and gravimetric characterization to define an operative window for plasma treatment conditions. According to the results obtained, the dry add-on content of thiourea improved up to 38%, thanks to the increase of the fabric surface activation. The effectiveness of plasma treatment resulted in an absolute increase up to 2% in limiting oxygen index (LOI) performance with respect to untreated fabric. As a consequence, a drastic reduction of 50% in thiourea concentration was required to achieve a similar fire retardant performance for plasma-treated fabric. On the basis of these preliminary results, a design of experiment (DoE) methodology was applied to the selected parameters to build a suitable response surface, experimentally validated, and to identify optimized treatment conditions. At the end, a final LOI index up to 43% has been reached.

Disposable Paper-Based Biosensors: Optimizing the Electrochemical Properties of Laser-Induced Graphene.

Laser-induced graphene (LIG) on paper substrates is a desirable material for single-use point-of-care sensing with its high-quality electrical properties, low fabrication cost, and ease of disposal. While a prior study has shown how the repeated lasing of substrates enables the synthesis of high-quality porous graphitic films, however, the process-property correlation of lasing process on the surface microstructure and electrochemical behavior, including charge-transfer kinetics, is missing. The current study presents a systematic in-depth study on LIG synthesis to elucidate the complex relationship between the surface microstructure and the resulting electroanalytical properties. The observed improvements were then applied to develop high-quality LIG-based electrochemical biosensors for uric acid detection. We show that the optimal paper LIG produced via a dual pass (defocused followed by focused lasing) produces high-quality graphene in terms of crystallinity, sp2 content, and electrochemical surface area. The highest quality LIG electrodes achieved a high rate constant k0 of 1.5 × 10-2 cm s-1 and a significant reduction in charge-transfer resistance (818 Ω compared with 1320 Ω for a commercial glassy carbon electrode). By employing square wave anodic stripping voltammetry and chronoamperometry on a disposable two-electrode paper LIG-based device, the improved charge-transfer kinetics led to enhanced performance for sensing of uric acid with a sensitivity of 24.35 ± 1.55 µA µM-1 and a limit of detection of 41 nM. This study shows how high-quality, sensitive LIG electrodes can be integrated into electrochemical paper analytical devices.

Graphene oxide incorporating carbon fibre-reinforced composites submitted to simultaneous impact and fire: Physicochemical characterisation and toxicology of the by-products.

The toxicological profile of particulates released from carbon fibre-reinforced composites (CFC) incorporating nanoadditives, under impact and fire conditions (e.g. aircraft crash), is unknown to date. Our aim was to investigate the effects of simultaneous impact and fire on the physicochemical features of the particles released from CFCs produced from a graphene oxide (GO)-reinforced epoxy resin and the consequences on its toxicological profile. CFC samples with (CFC + GO) or without GO (CFC) were subjected to simultaneous impact and fire through a specific setup. Soot and residues were characterised and their toxicity was compared to that of virgin GO. Virgin GO was not cytotoxic but induced pro-inflammatory and oxidative stress responses. The toxicity profile of CFC was similar for soot and residue: globally not cytotoxic, inducing a pro-inflammatory response and no oxidative stress. However, an increased cytotoxicity at the highest concentration was potentially caused by fibres of reduced diameters or fibril bundles, which were observed only in this condition. While the presence of GO in CFC did not alter the cytotoxicity profile, it seemed to drive the pro-inflammatory and oxidative stress response in soot. On the contrary, in CFC + GO residue the biological activity was decreased due to the physicochemical alterations of the materials.

Effects of Water and Chemical Solutions Ageing on the Physical, Mechanical, Thermal and Flammability Properties of Natural Fibre-Reinforced Thermoplastic Composites.

Biocomposites comprising a combination of natural fibres and bio-based polymers are good alternatives to those produced from synthetic components in terms of sustainability and environmental issues. However, it is well known that water or aqueous chemical solutions affect natural polymers/fibres more than the respective synthetic components. In this study the effects of water, salt water, acidic and alkali solutions ageing on water uptake, mechanical properties and flammability of natural fibre-reinforced polypropylene (PP) and poly(lactic acid) (PLA) composites were compared. Jute, sisal and wool fibre- reinforced PP and PLA composites were prepared using a novel, patented nonwoven technology followed by the hot press method. The prepared composites were aged in water and chemical solutions for up to 3 week periods. Water absorption, flexural properties and the thermal and flammability performances of the composites were investigated before and after ageing each process. The effect of post-ageing drying on the retention of mechanical and flammability properties has also been studied. A linear relationship between irreversible flexural modulus reduction and water adsorption/desorption was observed. The aqueous chemical solutions caused further but minor effects in terms of moisture sorption and flexural modulus changes. PLA composites were affected more than the respective PP composites, because of their hydrolytic sensitivity. From thermal analytical results, these changes in PP composites could be attributed to ageing effects on fibres, whereas in PLA composite changes related to both those of fibres present and of the polymer. Ageing however, had no adverse effect on the flammability of the composites.

Flax/PP and Flax/PLA Thermoplastic Composites: Influence of Fire Retardants on the Individual Components.

This study is based on previously reported reaction to fire properties of flax fibre-reinforced polymeric (polypropylene, PP and polylactic acid, PLA) composites, prepared by pre-treating the fabrics with different fire retardants (FRs) prior to composite preparation. It was observed that while all of these treatments were very effective in flax/PLA in terms of achieving a V-0 rating in a UL-94 test, only an organophosphonate FR was capable of achieving a V-0 rating for flax/PP. However, all fire-retardant treatments impaired the mechanical properties of the composites; the reduction was more in flax/PLA compared to flax/PP composites. To understand these effects further, here thermal analysis and pyrolysis combustion flow calorimetry of the composites and each component separately treated with FRs have been conducted and the results analysed in terms of the effect on each component so as to observe any interaction between the different components. The results indicated that in flax/PLA composites, the water released during FR catalysed dehydration-decomposition of flax may hydrolyse PLA, changing decomposition pathway of PLA to produce less flammable volatile, hence resulting in reduced flammability.

Potential Synergism between Novel Metal Complexes and Polymeric Brominated Flame Retardants in Polyamide 6.6.

While environmental concerns have caused polymeric brominated primary flame retardants (PolyBrFRs) to be effective replacement monomeric species, few alternatives for antimony trioxide (ATO) have been developed beyond the zinc stannates (ZnSs). Previous research, which explored the interactions of aluminium (AlW), tin (II) (SnW) and zinc (ZnW) tungstates with several phosphorus-containing flame retardants in polyamide 6.6 (PA66), is extended to two PolyBrFRs: brominated polystyrene (BrPS), and poly(pentabromobenzyl acrylate) (BrPBz). On assessing the effect of each tungstate on the thermal degradation and flammability in combination with each PolyBrFR using TGA, UL94, LOI, cone calorimetry and TGA-FTIR, only ZnW and SnW showed significant increases in LOI (>26 vol.%). Both ZnW-BrPS- and ZnW-BrPBz-containing formulations yielded average UL94 ratings ≥ V-2 and TGA char residues (corrected for metals content at 500 °C) in air > 15 wt.%. BrPS-containing samples, especially those containing ZnW and SnW, generated peak heat release rates approximately 50% lower than the equivalent BrPBz samples. These reductions did not correlate with respective increases in LOI, suggesting that tungstate-PolyBrFR combinations influence pre-ignition differently to post-ignition behaviour. Calculated synergistic effectivities indicate that ZnW functions as a synergist in both pre- and post-ignition stages, especially with BrPS. TGA-FTIR and char analyses showed that, in addition to the vapour-phase activity normally associated with PolyBrFRs, condensed-phase processes occurred, especially for the ZnW-PolyBrFR combinations. Additionally, ZnW demonstrated significant smoke-suppressing properties comparable with zinc stannate (ZnS).

Organo-Inorganic Hybrid Intumescent Fire Retardant Coatings for Thermoplastics Based on Poly(Vinylphosphonic Acid).

Thin coatings of crosslinked poly(vinylphosphonic acid), PVPA, display good adhesion and excellent intumescent, fire-retardant barrier properties when applied to the surfaces of a typical thermoplastic, such as poly(methyl methacrylate), but perform relatively poorly in water-soak tests. To strengthen and further improve the barrier properties of the intumescent char and to make the coating more hydrophobic, PVPA has been complexed with various inorganic and organic species. The chars formed from coatings of some of these hybrid materials are less friable than chars from coatings synthesized from crosslinked PVPA alone, and show higher levels of water tolerance with no significant reduction in dry adhesion to the substrate.

Flame Retardancy Index for Thermoplastic Composites.

Flame Retardancy Index, FRI, was defined as a simple yet universal dimensionless criterion born out of cone calorimetry data on thermoplastic composites and then put into practice for quantifying the flame retardancy performance of different polymer composites on a set of reliable data. Four types of thermoplastic composites filled with a wide variety of flame retardant additives were chosen for making comparative evaluations regardless of the type and loading level of the additive as well as the irradiance flux. The main features of cone calorimetry including peak of Heat Release Rate (pHRR), Total Heat Release (THR), and Time-To-Ignition (TTI) served to calculate a dimensionless measure that reflects an improvement in the flame retardancy of nominated thermoplastic composites with respect to the neat thermoplastic, quantitatively. A meaningful trend was observed among well-classified ranges of FRI quantities calculated for the studied dataset on thermoplastic composites by which "Poor", "Good", and "Excellent" flame retardancy performances were explicitly defined and exhibited on logarithmic scales of FRI axis. The proposed index remains adaptable to thermoplastic systems whatever the polymer or additive is.

Flame Retardant Polyamide Fibres: The Challenge of Minimising Flame Retardant Additive Contents with Added Nanoclays.

This work shows that halogen-free, flame retarded polyamide 6 (PA6), fabrics may be produced in which component fibres still have acceptable tensile properties and low levels (preferably ≤10 wt %) of additives by incorporating a nanoclay along with two types of flame retardant formulations. The latter include (i) aluminium diethyl phosphinate (AlPi) at 10 wt %, known to work principally in the vapour phase and (ii) ammonium sulphamate (AS)/dipentaerythritol (DP) system present at 2.5 and 1 wt % respectively, believed to be condense phase active. The nanoclay chosen is an organically modified montmorillonite clay, Cloisite 25A. The effect of each additive system is analysed in terms of its ability to maximise both filament tensile properties relative to 100% PA6 and flame retardant behaviour of knitted fabrics in a vertical orientation. None of the AlPi-containing formulations achieved self-extinguishability, although the presence of nanoclay promoted lower burning and melt dripping rates. The AS/DP-containing formulations with total flame retardant levels of 5.5 wt % or less showed far superior properties and with nanoclay, showed fabric extinction times ≤ 39 s and reduced melt dripping. The tensile and flammability results, supported by thermogravimetric analysis, have been interpreted in terms of the mechanism of action of each flame retardant/nanoclay type.

The Effects of Thermophysical Properties and Environmental Conditions on Fire Performance of Intumescent Coatings on Glass Fibre-Reinforced Epoxy Composites.

Intumescent coatings are commonly used as passive fire protection systems for steel structures. The purpose of this work is to explore whether these can also be used effectively on glass fibre-reinforced epoxy (GRE) composites, considering the flammability of the composites compared to non-flammable steel substrate. The thermal barrier and reaction-to-fire properties of three commercial intumescent coatings on GRE composites have been studied using a cone calorimeter. Their thermophysical properties in terms of heating rate and/or temperature dependent char expansion ratios and thermal conductivities have been measured and correlated. It has been suggested that these two parameters can be used to design coatings to protect composite laminates of defined thicknesses for specified periods of time. The durability of the coatings to water absorption, peeling, impact, and flexural loading were also studied. A strong adhesion between all types of coatings and the substrate was observed. Water soaking had a little effect on the fire performance of epoxy based coatings. All types of 1 mm thick coatings on GRE helped in retaining ~90% of the flexural property after 2 min exposure to 50 kW/m² heat flux whereas the uncoated laminate underwent severe delamination and loss in structural integrity after 1 min.

Influence of Flame Retardants on the Melt Dripping Behaviour of Thermoplastic Polymers.

Melt flow and dripping of the pyrolysing polymer melt can be both a benefit and a detriment during a fire. In several small-scale fire tests addressing the ignition of a defined specimen with a small ignition source, well-adjusted melt flow and dripping are usually beneficial to pass the test. The presence of flame retardants often changes the melt viscosity crucially. The influence of certain flame retardants on the dripping behaviour of four commercial polymers, poly(butylene terephthalate) (PBT), polypropylene (PP), polypropylene modified with ethylene-propylene rubber (PP-EP) and polyamide 6 (PA 6), is analysed based on an experimental monitoring of the mass loss due to melt dripping, drop size and drop temperature as a function of the furnace temperature applied to a rod-shaped specimen. Investigating the thermal transition (DSC), thermal and thermo-oxidative decomposition, as well as the viscosity of the polymer and collected drops completes the investigation. Different mechanisms of the flame retardants are associated with their influence on the dripping behaviour in the UL 94 test. Reduction in decomposition temperature and changed viscosity play a major role. A flow limit in flame-retarded PBT, enhanced decomposition of flame-retarded PP and PP-EP and the promotion of dripping in PA 6 are the salient features discussed.