Sustainable furfuryl alcohol-based flame retardants with regular spherical morphology: Endow polypropylene with excellent flame retardancy, smoke suppression, and mechanical properties

Preparation of polyolefins possessing superior flame retardant and mechanical properties has always been a hot research topic. Herein, a novel high-performance flame retardant was designed and prepared to address the dilemma between flame retardancy and mechanical properties. Through self-stabilized precipitation polymerization of furfuryl alcohol (FA) and maleic anhydride (Ma), followed by successive amination and phosphorylation treatment, bio-based phosphorylated FMa microspheres (P-FMa) were successfully obtained. Benefiting from strong synergistic effect between P-FMa and ammonium polyphosphate (APP), the polypropylene (PP)/APP/P-FMa composites exhibited excellent flame retardant and smoke suppression properties. At a dosage of only 19 wt% APP/P-FMa, the PP/APP/P-FMa reached UL-94 V-0 rating and a limiting oxygen index of 32.2 %, and the peak heat release rate and peak smoke production rate decreased by 76.1 % and 52.6 % compared with neat PP, respectively, due to the formation of denser and firmer char layer. Notably, the tensile strength of PP/APP/P-FMa maintained at a high level of 43.2 MPa. More importantly, the impact strength reached 10.5 kJ/m2, increase by 138.6 % compared to PP/APP, mainly attributed to improved dispersion and compatibility between APP/P-FMa and PP matrix. Owing to its ability to simultaneously improve flame retardant and mechanical properties, P-FMa possesses great potiential as a high-performance flame-retardant filler.