A reactive melamine-DOPO based flame retardant for superior thermal stability and flame retardancy in rigid polyurethane foam

The flame-retardant effect of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) and its derivatives in reducing the flammability of polymeric materials are well known. In this study, flame-retardant rigid polyurethane foams (FR-RPUF) were synthesized using a melamine-DOPO-based flame-retardant (MDFR). Additionally, MDFR was also used for preparation of a flame-retardant elastomeric polyurethane (FR-PUE). The chemical structure and thermal properties of the FR-RPUF and FR-PUE samples were studied with Fourier transform infrared (FTIR), field emission-scanning electron microscopy (FE-SEM), and thermogravimetric analysis (TGA). TGA results revealed that the incorporation of MDFR into the PU matrix significantly increased the char residue. The char residue of FR-RPUF with 0.5 wt% MDFR increased from 4.75% to 44.36%, as compared to the pure RPUF. Results from the microscale combustion calorimeter (MCC) test illustrated that the peak of heat release rate (pHRR), total heat release (THR), and heat release capacity (HRC) of the FR-RPUF and FR-PUE samples were reduced, as compared to the pure PU samples. The pHRR value of FR-RPUF with 3 wt% of MDFR decreased 12%, as compared to the pure RPUF, while the pHRR was obtained 34% lower than of the pure PUE. Furthermore, FR-RPUFs successfully passed the UL94 testing, achieving a V-0 grade.