Flame Retardant Intumescent Polyamide 11-Carbon Nanofiber Nanocomposites: Thermal and Flammability Properties
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Flame Retardant Intumescent Polyamide 11-Carbon Nanofiber Nanocomposites: Thermal and Flammability Properties Si Chon Lao1, Joseph H Koo1, Alexander Morgan2, Hung-Kai Jor1, Khiet Nguyen1, Gerhardt Wissler3, Louis Pilato3, and Zhiping Luo4 1 Mechanical Engineering, University of Texas at Austin, 1 University Station C2200, Austin, TX, 78712 2 University of Dayton Research Institute, 300 College Park, Dayton, OH, 45469 3 KAI, LLC, Austin, TX, 78739 4 Texas A&M University, College Station, TX, 77843 ABSTRACT Current polyamide 11 and 12 are lacking in fire retardancy and high strength/high heat resistance characteristics for fabricated parts that are required for performance driven applications. The introduction of selected nanoparticles such as carbon nanofibers (CNFs), combined with a conventional intumescent flame retardant (FR) additive into the polyamide 11/polyamide 12 (PA11/PA12) by melt processing conditions has resulted in a family of intumescent polyamide nanocomposites. These intumescent PA11 and PA12 nanocomposites exhibit enhanced polymer performance characteristics, i.e., fire retardancy, high strength, and high heat resistance and are expected to expand the market opportunities for resin manufacturers. The overall objective of this research is to develop improved PA11 and PA12 polymers with enhanced flame retardancy, thermal, and mechanical properties for selective laser sintering (SLS) rapid manufacturing. Arkema RILSAN® PA11 polymer was examined with CNFs and Clairant Exolit® OP 1230 intumescent FR additive. They were used to create a family of FR intumescent PA11-CNF nanocomposites. Transmission electron microscopy (TEM) was used to determine the degree of CNFs and intumescent FR additive dispersion in PA11. Injection molded specimens were fabricated for material properties measurements. Thermal stability of these polymer nanocomposites (PNs) was examined by TGA. Flammability and thermal properties of these PNs were obtained using the cone calorimeter, UL 94 test method, and heat deflection temperature. INTRODUCTION Flame retardant (FR) additives such as inorganic metal oxides/hydroxides or halogens with or without phosphorous and nitrogen containing materials are required in conventional methods to modify flammable thermoplastic materials as FR products [1]. Large amounts of FR additives (>30%) are necessary in those methods to make FR thermoplastics. In many cases a reduction of mechanical properties, such as toughness, melt flow, and/or release of smoke and toxic emissions, occurs when the modified thermoplastic is burning. The incorporation of nanoparticles has been shown to be an effective method for developing FR thermoplastic polymer by twin-screw extrusion process. Small amounts of nanoparticles (7%) would yield relatively good enhancement of flame retardancy, but the mechanical properties of the resulting polymer nanocomposites would be compromised. Thus the major technical objective of this research program is the enhancement of the FR properties of the PA11 nanocomposites while
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