Synthesis and application of a dual functional P/N/S‐containing microsphere with enhanced flame retardancy and mechanical strength on EP resin

Abstract

A phosphazene derivative flame retardant with a highly cross‐linked microsphere structure, named poly(cyclotriphosphazene‐c‐sulfonyldiphenol) (PCPS) microspheres, were synthesized by 1‐pot reaction and then applied on flame retarded epoxy (EP) resin. The microstructure and chemical composition of PCPS microspheres were characterized using scanning electron microscopy, transmission electron microscopy, and element mapping. The thermal stability of PCPS microspheres and PCPS/EP composites was explored through thermogravimetric analysis. Thermogravimetric data showed that the PCPS microspheres have excellent thermal stability, and the char yield is about 43% at the end of 800°C. The incorporation of PCPS microspheres significantly increased the char yield of PCPS/EP composites. The flammability was investigated by limited oxygen index tests and cone calorimeter. The limited oxygen index value of PCPS/EP composite was increased to 29.8 from 26.6 when 3 wt% of PCPS microspheres was added. Compared with neat EP, the flame retardancy was greatly improved. The peak heat release rate and smoke production rate of PCPS/EP composites were reduced by 45.0% and 43.6%, respectively. The mechanical properties including tensile strength and modulus were both improved due to the enhancement of PCPS microspheres. The PCPS microspheres act as a dual function for improving both the flame resistance and mechanical strength of PCPS/EP system.