Preparation of Microencapsulated Red Phosphorus and Its Flame-Retardant Application in PP Composites

In the present study, the melamine-formaldehyde prepolymer (MEP) was first synthesized at pH 8-8.5 under about 80 degrees C with melamine, formaldehyde, triethanolamine and methanol as the starting materials. Subsequently, the microencapsulated red phosphorus (MRP) was successfully prepared by in-situ polymerization at pH 5.5 under 65 degrees C, using MFP and red phosphorus (RP) powders as raw materials, and potassium persulphate (KPS) as catalyst. The obtained products were detected by differential scan calorimetry (DSC), scanning electron microscope (SEM), Fourier transform infrared (FUR) and X-ray photoelectron spectroscopy (XPS). It was found that KPS is useful in enhancing the reaction activity of MFP, which can make RP be well encapsulated by melamine-formaldehyde resin (ME) and reduce the reaction time. The DSC, SEM and XPS results show that it won't get well-encapsulated MRP only under acidic condition and without any KPS. When a proper quantity of K'S is employed, the RP particles can be almost completely-encapsulated by MF and the peak temperature of oxidation reaction for MRP is 480 degrees C, which is much higher than that of RP, extending the applications for MRP. The FTIR spectrum demonstrates that the coating material on the surface of RP accurately is ME, in agreement with the reference. Polyproplene (PP) composites with different formulations were prepared by melt extrusion. It was shown that the flame-retardant efficiencies are very low when the PP composites only contain MRP or MH. However, the flame-retardant property can obviously improve if MRP and MH are both used in the PP composites. When PP : MRP MH=100 (phr) : 15 (phr) : 50 (phr), the limited oxygen index of the MRP/MH/PP composite is 26%, and vertical firing ranks UL-94 V-0. In addition, the possible flame-retardant mechanism of the PP composites has also been discussed, and further verified by FTIR and Raman spectroscopy.