Search Results (1,833)

The development of high-performance flame-retardant (FR) polypropylene (PP) with high mechanical integrity remains a challenge. Herein, we demonstrate a synergistic flame retardancy system for PP achieved via partial substitution of piperazine pyrophosphate (PAPP) with 1 wt.% magnesium borate whiskers (MBW) for improved flame retardancy, and thermal and mechanical properties. The optimized PP/24PAPP/1MBW exhibits exceptional FR performance, driven by the formation of a highly ordered, continuous phosphorus–boron hybrid char in the condensed phase. Cone calorimetry test results reveal an 80% reduction in peak heat release rate, a 54% reduction in total heat release, and a 33% reduction in total smoke production compared to neat PP, while the UL-94 test confirms a V-0 rating with complete suppression of flaming drips. Morphological study of the char residue using Raman spectroscopy and SEM attributes this performance to enhanced char graphitization and structural coherence enabled by boron-mediated cross-linking. More importantly, this transformative flame retardancy performance is achieved without severe compromise to mechanical properties, retaining over 89% of the original tensile strength. This work confirms the PAPP/MBW system as a highly efficient, low-additive approach to creating advanced fire-safe polymer composites for engineering applications. Full article

The poor thermal stability of commercial polyethylene (PE) separators hinders the further application of lithium-ion batteries (LIBs), yet previous modifications struggle to balance between safety and electrochemical performance. This study proposes an interface modification strategy by forming a poly(melamine terephthalamide) (PTM) coating on the PE separator surface, constructing a “thermal–mechanical–electrochemical synergistic barrier”. The PTMs@PE separator achieves synergistic improvements in thermal shutdown behavior, thermal stability, mechanical strength, and electrochemical compatibility by taking advantage of the temperature-sensitive response of the PE separator, the flame-retardants of the rigid conjugated skeleton with the high nitrogen of PTM, and the electrolyte-affinity of its functional groups. Importantly, the principles between the molecular structure of the PTM coating and the thermal behavior is verified. The results demonstrate that PTM participates in the decomposition process of the PE separator and slows down the degradation rate of the PE chain structure, thereby resulting in a wide-temperature-range thermal shutdown temperature. The PTMs@PE effectively reduces the risk of runaway. The PTMs@PE separator achieves outstanding electrochemical compatibility, achieving a capacity retention rate of 99.27% at 2 C for 500 cycles. Notably, the separator shows high potential for scalable fabrication. This work provides a novel material system and technical pathway for developing highly safe and high-performance LIB separators. Full article

This study investigates the influence of surface-modified fly ash particles on the fire behavior of polyamide 6 (PA6) composites containing two types of flame retardants: melamine polyphosphate (MPP) and aluminum diethyl phosphinate (AlPi). The objective was to evaluate how interfacial modification of fly ash using amino-silane (APTES), glycidoxy-silane (GPTES), or titanate coupling agents affects dispersion, thermal stability, and combustion performance. A series of 18 formulations containing up to 25 wt% of additives was prepared by melt compounding and characterized by thermogravimetric analysis (TGA) and cone calorimetry. TGA results showed that MPP-based systems favored char formation, with residues up to 21%, whereas AlPi provided higher thermal stability (T₅₀% ≈ 445 °C). The incorporation of untreated or surface-treated fly ash improved both thermal stability and char yield, depending on the nature of the coupling agent. Cone calorimeter results confirmed a strong synergistic effect between flame retardants and fly ash. The peak heat release rate (pHRR) decreased by 65–75% compared to neat PA6, while total heat release (THR) and mass loss were also significantly reduced. Titanate-modified fly ash showed the most homogeneous dispersion and provided the highest residue and lowest pHRR values. Energy-dispersive X-ray (EDX) analyses confirmed enhanced phosphorus retention in the residues (up to 100%), evidencing the formation of stable inorganic species and protective ceramic-like structures. These results demonstrate that surface-modified fly ash can act as an efficient synergistic additive in PA6 flame-retardant formulations, simultaneously improving fire performance and promoting the valorization of industrial by-products for sustainable polymer design. Full article

The recycling of technical textile waste represents a major challenge due to the complex and multilayered structure of these materials. Firefighter protective clothing, mainly composed of high-performance aramid fibers combined with polymeric membranes and auxiliary textile components, is commonly landfilled or incinerated at the end of its service life, resulting in a significant environmental impact. This work utilized recycled aramid-rich textile waste obtained from end-of-life firefighter protective clothing as reinforcement for polyamide 6 to develop high-performance thermoplastic composites within a circular economy framework. Composites containing 15, 30, 45, and 60 wt.% of recycled textile waste were manufactured by melt compounding followed by injection molding. In addition, a selected formulation containing 30 wt.% reinforcement was compatibilized using an amino-functional silane to improve interfacial adhesion. The materials were systematically characterized in terms of tensile properties, thermal behavior, thermomechanical performance, water uptake, flammability, colorimetric properties, and fracture morphology by field emission scanning electron microscopy. The results revealed a pronounced increase in stiffness and thermomechanical stability, with tensile strength increasing from approximately 65 MPa for neat PA6 up to 78 MPa at 30 wt.% reinforcement, and elastic modulus exceeding 5000 MPa at high reinforcement contents. An optimal balance between mechanical performance and ductility was achieved at 30 wt.% reinforcement, while higher contents enabled a substantial extension of the service temperature range, with HDT values increasing from 55 °C for neat PA6 up to 173 °C for highly reinforced systems. FESEM analysis confirmed improved interfacial adhesion in silane-compatibilized systems, explaining the enhanced mechanical and thermomechanical behavior. Furthermore, the incorporation of recycled aramid-rich textile waste led to a significant improvement in flame retardancy, enabling UL-94 V-0 classification at 30 wt.% reinforcement and above, without the use of additional flame-retardant additives, enabling UL-94 V-0 classification without additional flame-retardant additives. Overall, this study demonstrates the technical feasibility and high added-value potential of valorizing firefighter protective clothing waste into advanced PA6-based composites with enhanced mechanical, thermal, and fire-resistant properties, providing a sustainable route for the valorization of high-performance textile waste. Full article

Gypsum-based fire protection relies on thermally activated dehydration, where chemically bound water is released and evaporated, thereby providing an endothermic heat sink that delays heat penetration through assemblies. In parallel, inorganic hydrated salts are increasingly used as flame-retardant additives in gypsum-based systems to enhance heat absorption over specific temperature ranges. Fire simulation tools and performance-based fire engineering approaches require reliable kinetic data and reaction enthalpies that can be implemented as coupled thermal–chemical source terms. However, additive-specific kinetic datasets remain limited, particularly under restricted vapor exchange conditions representative of porous construction materials. This work investigates the thermal decomposition behavior and dehydration kinetics of Aluminum Trihydrate (Al(OH)₃, ATH), Magnesium Hydroxide (Mg(OH)₂, MDH), Calcium Aluminate Sulfate (3CaO·Al₂O₃·3CaSO₄·32H₂O, CAS), and Magnesium Sulfate Heptahydrate (MgSO₄·7H₂O, ESM) with emphasis on vapor-restricted conditions representative of confined porous systems. Differential scanning calorimetry (DSC) experiments were conducted at three heating rates (2, 10, and 20 K/min for MDH, CAS and ESM and 20, 40 and 60 K/min for GB-ATH) up to 600 °C using pinhole crucibles to simulate autogenous vapor pressure. The thermal analysis indicates that ATH and MDH exhibit predominantly single-step dehydration behavior, while ESM shows a complex multi-step mechanism. Although CAS presents a single dominant thermal peak in the DSC signal, the isoconversional analysis reveals a multi-stage reaction behavior, demonstrating that peak-based interpretation alone may be insufficient for such systems. Kinetic parameters were determined using both model-free (Starink) and model-fitting approaches in accordance with the recommendations of the Kinetics Committee of the International Confederation for Thermal Analysis and Calorimetry (ICTAC). All reactions were consistently described using the Avrami–Erofeev model as an effective phenomenological representation of the conversion behavior. The extracted kinetic triplets were validated through numerical simulations, showing good agreement with experimental conversion and reaction rate data. The resulting kinetic parameters and dehydration enthalpies provide a physically consistent dataset for the description of dehydration processes under restricted vapor exchange. These results support the development of thermochemical models for gypsum-based systems; however, their transferability to full-scale assemblies remains subject to validation under coupled heat- and mass-transfer conditions. Full article

In this work, poly(acrylic acid)-based layers were injected to form a sandwich layer between the cationic and anionic species for a compact and effective fire-retardant coating on cotton fabric using the layer-by-layer coating technique. From the SEM analysis, as the number of tri-layers increases, the attachment intensity increases, as can be seen for poly(acrylic acid) chitosan and bentonite clay PCB-5TL (the highest tri-layers), while in the case of halloysite-based coatings, as the number of tri-layers increases, instead of attachment, the agglomeration increases due to the high surface area of halloysite nanoclay tubes. FTIR and UV confirmed the finding from the new peak entry and an increase in thickness. The highest thermal residue, ~18%, was obtained for poly(acrylic acid) chitosan and halloysite nanoclay PCH-5TL with a maximum degradation peak intensity at ~389 °C. From the flammability and after-burning SEM investigation test, it was observed that the halloysite-based coating with a higher number of layers offered higher resistance against the flame spread and ignition and, thus, produced a higher amount of char. Full article

Sodium metal batteries (SMBs) are promising energy storage systems, yet their practical application is hindered by unstable solid electrolyte interphases (SEIs) and safety issues associated with flammable electrolytes. Although the flame-retardant solvent trimethyl phosphate (TMP) is widely used in rechargeable batteries, its application in SMBs remains constrained due to uncontrolled and accumulated parasitic reactions with sodium metal anodes. Here, we propose a novel synergistic strategy that combines a fluorinated additive (FEC) with a low-cost, high-concentration NaClO₄ to stabilize the electrode–electrolyte interface in TMP-based electrolytes. This approach enables the formation of a robust, NaF-rich SEI while restructuring the Na⁺ solvation sheath to coordinately trap TMP molecules, thereby suppressing parasitic reactions between sodium metal and TMP. As a result, the Na|Na₃(VOPO₄)₂F cell achieves exceptional cycling stability with 89.04% capacity retention over 1000 cycles at 1C. This work provides a cost-effective and practical pathway toward safe and long-lasting SMBs using non-flammable phosphate electrolytes. Full article

With the development of the information society, display technologies are evolving toward greater flexibility and advanced performance. Dye-based polyvinyl alcohol (PVA) complex films have gained widespread attention for their excellent resistance to high temperature and humidity. This review systematically summarizes the research progress of dye-based polarizers using PVA as the substrate, focusing on their preparation principles, film properties, and impacts on optical performance. Strategies to enhance optical properties and durability are discussed, including dye molecular optimization, formulation design, control of the dyeing process, and PVA substrate film modification. Notably, improving interfacial interactions between dyes and PVA enhances molecular orientation and stability, while PVA modification improves mechanical properties, water resistance, thermal stability, and flame retardancy. By demonstrating these enhanced comprehensive properties, this review highlights the potential of PVA–based films to serve as high-performance platforms for the development of next-generation multifunctional optical and display materials. Finally, the challenges and development directions of dye-based PVA complex films for optical applications in harsh environments are prospected. This review provides a theoretical basis and technical pathway for the design and development of next-generation high-performance composite polarizers. Full article

Epoxy resins (EP) are widely used in aerospace, electronics, and coatings due to their excellent mechanical and thermal properties. However, their inherent flammability and brittleness limit high-end applications. In this work, a novel reactive flame retardant epoxy monomer (EP-DVGA) containing DOPO and triazole units was designed and synthesized via a molecular engineering strategy. The chemical structure was confirmed by FTIR and NMR. A series of modified epoxy thermosets were prepared by co-curing EP-DVGA with bisphenol A epoxy resin (E51) using DDM as curing agent. The results showed that EP-DVGA significantly enhanced flame retardancy: At 16.31 wt% loading, the limiting oxygen index increased from 25.9% to 34.3% with UL-94 V-0 rating, and cone calorimetry revealed 73.2% and 69.2% reductions in peak heat release rate and total heat release, respectively. Mechanistic studies demonstrated a dual flame retardant effect involving phosphorus radical quenching in the gas phase and formation of a dense graphitized char layer in the condensed phase. Remarkably, EP-DVGA also improved mechanical properties—impact strength increased by 47% and tensile strength by 33.1% at optimal loadings—attributed to energy dissipation through reversible hydrogen bonding and π–π interactions. This molecular design successfully overcomes the traditional trade-off between flame retardancy and mechanical performance, offering a promising strategy for developing high-performance intrinsically flame retardant epoxy materials. Full article

Polymer cement-based coatings (PCC) have great potential in protecting underground structures, while their flame -retardancy is limited by the flammability of the polymer components. Developing multifunctional inorganic fillers that can enhance both mechanical properties and flame retardancy is crucial for improving the safety and durability of the coatings. In this study, an ettringite (AFt) modified by amphiphilic group and aluminum hydroxide (AH) was subjected to surface functionalization treatment and then incorporated into the PCC to enhance the overall performance of the material. The tensile strength and bond strength of the coatings modified by amphiphilic group with AFt were increased by 27.7% and 22.4%, respectively. Meanwhile, the flame burn time, flameless burn time, and carbonization length were reduced by 89.1%, 80.6%, and 90.2%, respectively, and the limiting oxygen index (LOI) increased by 28.9%. The amphiphilic groups act as molecular bridges that couple the inorganic modified AFt with the organic VAE phase, thereby strengthening the organic–inorganic interface and promoting a more integrated polymer–cement network. Meanwhile, the well-dispersed inorganic phases provide endothermic dehydration and a protective residue during heating, jointly improving the mechanical reliability and fire safety of the PCC. Full article

The need to reduce polyurethane (PU) foam waste has encouraged the development of sustainable foam formulations based on recycled raw materials and environmentally friendly additives, addressing both waste management and comparable foam properties to those based on fossil resources. In the present investigation, more sustainable water-blown rigid PU foams were investigated using recycled polyol and halogen-free flame retardants (FRs) for fire-resistant insulation applications. Two series of foam formulations were prepared: a first series with virgin polyol and the inclusion of a halogen-free FR additive (6 wt%) and a second series with recycled polyol (10% added respect to the total polyol) and halogen-free FR additives (6 wt%). Two types of FR were used: FR900, specifically identified as 3,9-Dimethyl-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane-3,9-dioxide, in powder form with 24% phosphorus content and reactive polyol based FR140, an oligomeric ethyl ethylene phosphate, in liquid form with 19% phosphorus content. The density, cellular structure, aged thermal conductivity, dimensional and hydrolytic stability, fire properties, and mechanical properties were characterized for novel foamed systems. Rigid foamed materials with very low densities around 50 kg/m³ were obtained. On the one hand, the inclusion of FR900 into the PU formulation containing virgin polyol generated foam with the lowest thermal conductivity (36.10 mW/mK) due to the smaller open cell content (11.7%) and cell size reduction (433 microns). On the other hand, the inclusion of recycled polyol reduced the foam density by 6 kg/m³ (44.1 kg/m³), increased the cell size average (848 microns) and open cell content (15.1%), maintained thermal conductivity (38.73 mW/mK), slightly improved the fire properties, and worsened the mechanical properties in comparison with the PU reference containing only virgin polyol. The results obtained by the foam containing recycled polyol and 6% FR900 are remarkable, presenting an increase in density (50.3 kg/m³) and in open cell content (73%), but a very high reduction in cell size (465 microns) and thus a low value of thermal conductivity of 37.04 mW/mK with respect to the reference material containing recycled polyol. Moreover, this PU foam containing recycled polyol and FR900 offered improved fire resistance (148.2 kW/m² of Maximum Average Rate of Heat Emission (MARHE), 179.1 kW/m² of Maximum Heat Release Rate (HRRmax), and 24.6 MJ/m² of Total Heat Release (THR)) and mechanical properties (6.97 MPa of Young’s modulus and 0.24 MPa of collapsed stress) for the construction sector. The inclusion of FR140 does not improve the properties of the foam system containing recycled polyol, mainly due to the deterioration of the cellular structure (in the open cell content and cell size). Full article

Conventional separators for lithium metal batteries suffer from poor thermal stability, flammability, and limited mechanical strength. In this study, we report a self-reinforced aramid separator integrated with Li₇La₃Zr₂O₁₂ (LLZO) via a sodium–naphthalene-based selective dissolution strategy. Controlled partial disruption of hydrogen bonding in copolymerized aramid enables the formation of a hierarchical structure consisting of intact fibers and nanofibrillar networks, thereby providing intrinsic mechanical reinforcement without binders. The separator maintains structural integrity up to ~400 °C and retains over 70% weight at 600 °C, exhibiting self-extinguishing behavior (LOI > 30). Puncture strength is more than three times higher than Celgard^®, while LLZO integration doubles the ionic conductivity along with excellent electrolyte wettability. This synergistic design provides a promising route toward intrinsically safe and high-performance lithium metal battery separators. Full article

In the framework of plastic circularity, managing end-of-life plastics containing flame-retardant (FR) additives represents a significant challenge. Although FRs are essential for enhancing fire safety in polymeric materials, many FR-containing products are never exposed to fire during their service life. As a result, substantial amounts of still-active FR remain in plastic waste streams. Since mechanical recycling is currently the most widely implemented strategy for plastic waste management, it is crucial to evaluate whether this process affects the flammability and combustion behavior of FR plastics. In this study, polypropylene (PP) containing 21 wt.% intumescent FR (IFR) was reprocessed up to five times to simulate mechanical recycling. After each cycle, the materials were systematically characterized in terms of rheological, morphological, combustion, and mechanical behavior. Although the agglomeration of IFR particles was observed after multiple cycles, the materials maintained stable processability and thermal stability. Importantly, the charring efficiency of the IFR system was preserved, resulting in consistent flammability performance; furthermore, all reprocessed samples achieved UL 94 V-0 classification and exhibited comparable limited oxygen index values. Mechanical properties were likewise largely maintained. Overall, these findings demonstrate that mechanical recycling represents a viable end-of-life strategy for this PP/IFR system, supporting its compatibility with circular material flow. Full article

Scalable halogen-free flame-retardant textile finishes remain challenging, particularly regarding laundering durability and industrially viable processing. Here, two phytate flame retardants, poly(vinylammonium) phytate (PVAmPA, partly bio-based) and chitosan phytate (ChiPA, fully bio-based), were applied to cotton (CO), polyester (PET), and a CO/PET blend by a single-step, binder-assisted coating. Both coatings suppressed surface flaming in ISO 15025 on all substrates. Although laundering at 40 °C caused systematically higher wash-off for ChiPA, surface flame suppression was retained for most coated fabrics, with the exception of ChiPA on CO and PVAmPA on PET. Thermogravimetric analysis showed earlier decomposition and increased residue formation for both systems, with the residue at 700 °C increasing from 4.5% to 18.2% for CO_PVAmPA and from 4.5% to 15.2% for CO_ChiPA. In microscale combustion calorimetry, PVAmPA reduced the heat release capacity (HRC) from 251 to 168 J/(g·K) for CO/PET, whereas ChiPA showed its strongest effect on PET, reducing HRC from 413 to 222 J/(g·K). Gas-phase analyses indicated enhanced water release for both coatings and additional NH₃ evolution for PVAmPA. Overall, binder-assisted, single-step phytate coatings provide a scalable route to halogen-free flame retardancy, with PVAmPA showing the most robust overall durability and ChiPA offering a fully bio-based alternative with strong substrate-dependent performance. Full article