Intercalated kaolinite with ammonium dihydrogen phosphate as an effective flame retardant to enhance the flame retardance and smoke suppression of epoxy resins

Abstract

AbstractTo improve the compatibility and flame retardance of kaolinite (Kaol) in polymeric materials, ammonium dihydrogen phosphate (ADP) was intercalated into kaolinite to obtain a novel intercalated kaolinite (K‐ADP) for enhancing thermal stability, flame retardance, smoke suppression, and mechanical performance of epoxy resins (EPs). The results show that the presence of K‐ADP exerts a more positive effect on reducing the heat release and smoke generation of EPs than the same addition of Kaol. Condensed phase analysis shows that EP/K‐ADP composite generates more aromatic cross‐links in the condensed phase to reinforce the compactness and intumescence of char compared to EP/Kaol composite. Especially, 5 wt% K‐ADP confers a 43.7% reduction in peak heat release rate value and a 36.3% reduction in peak smoke production rate value to EP. Toxic gases analysis shows that K‐ADP conduces to inhibiting the release of combustible gases including isocyanates and aromatic volatiles, and generating incombustible gases including ammonia and carbon dioxide to reduce the intensity of EP combustion. The mechanical test shows that K‐ADP imparts less adverse impact on mechanical behavior to EP composites than Kaol due to the good dispersion and compatibility between K‐ADP with EP matrix.