Facile synthesis of aluminum branched oligo(phenylphosphonate) submicro-particles with enhanced flame retardance and smoke toxicity suppression for epoxy resin composites.

A novel and submicro-scale aluminum branched oligo(phenylphosphonate) (AHPP) has been successfully synthesized and embedded into a polymeric substrate to improve the fire safety of epoxy resin (EP). The chemical structures of intermediates and target products were characterized using the nuclear magnetic resonance spectroscopy, X-ray diffraction and Fourier transform infrared analysis. Morphology analysis confirmed that all of the as-synthesized AHPP submicro-particles are mutually well-separated. Combustion results demonstrated that the limiting oxygen index value is increased to 30.5% from 23.5% while the PHRR and THR are decreased by ca. 68.1% and 41.2%, respectively for the EP/AHPP-7.5 composite compared to the corresponding values for pure EP. In addition, the binary blends display the satisfying smoke toxicity suppression performance during combustion. The total smoke production and the total CO yield for EP/AHPP-7.5 are dramatically reduced by 62.0% and 32.3%, respectively, which may mainly be ascribed to the catalytic carbonization performance of the polymers and formation of Al2O3 layers on the surface of the char residues. As a result, the findings in this study enabled the submicro-scale phosphorus-containing flame retardant to be a potential candidate as an efficient additive for reducing smoke toxicity of polymer composites.