A novel macromolecular phosphorus-nitrogen containing flame retardant for polycarbonate

In this paper, an innovative macromolecular phosphorus-nitrogen containing flame retardant (PDPSB) was successfully designed and synthesized to investigate its impact on the flame retardancy, burning behavior, thermal stability, mechanical properties of polycarbonate (PC) composites. Furthermore, an in-depth exploration of the potential flame-retardant mechanism was conducted. The combustion results indicated that PC-3 with 3 wt% PDPSB reached V-0 rating in UL-94 test and showed a high limiting oxygen index (LOI) of 33.0 %. Compared to pure PC, the values for peak of heat release rate (PHRR), total heat release (THR) and total smoke production (TSP) of PC-3 were decreased by 37.9 %, 11.1 % and 4.9 %, respectively. It was noteworthy that the amount of char residue for PC-3 was raised from 7.4 % for pure PC to 15.8 % with increasing 113.5 %. The thermogravimetric analysis (TGA) results under N2 atmosphere revealed that PDPSB possessed preferable thermal stability with initial decomposition temperature (Tinitial) of 342.6 °C and higher char residue yield of 48.4 %. With increasing the amount of PDPSB, the maximum mass loss rate (Rpeak) was reduced and the char residue yield was increased for PC/PDPSB composites. In addition, the mechanical properties of PC/PDPSB composites were well maintained due to the good compatibility and dispersion between PDPSB and PC matrix. The tensile, flexural and izod impact strength of PC-3 were weakened by 4.3 %, 1.7 % and 16.8 % in comparison of pure PC, respectively. Based on the investigation into the flame-retardant mechanism of PDPSB, the excellent flame retardance of PC/PDPSB composites has been validated. In gaseous, the release of pyrolysis gases was suppressed and active radicals were captured by generated phosphorus free radicals. In condensed phase, the stable char residue with phosphorus and nitrogen elements acted as a barrier to hinder heat, flame and oxygen. This high-efficient single-component multifunctional additive presented a novel approach to the development of fire-resistant polymers with enhanced performance characteristics.