Polypropylene (PP), as a general thermoplastic polymer, is broadly used in different fields. However, the high flammability, melt dripping and poor mechanical properties of PP are a constraint to the expansion of its applications. In this paper, PP composites containing a combination of a phenethyl-bridged DOPO derivative (PN-DOPO) and organic montmorillonite (OMMT) were prepared via melt blending. The synergistic effects of PN-DOPO and OMMT on the flame retardancy, thermal stability and mechanical properties of PP composites were investigated systematically. The results showed that 20 wt% addition of PN-DOPO with OMMT improved the flame retardancy of PP composites. In particular, the introduction of 17 wt% PN-DOPO and 3 wt% OMMT increased the LOI values of the PP matrix from 17.2% to 23.6%, and the sample reached the V-0 level and reduced the heat release rate and total heat release. TGA indicated that OMMT could improve the thermal stability of the PP/PN-DOPO blends and promote the char residues of PP systems. Rheological behaviour showed a higher storage modulus, loss modulus and complex viscosity of PP/PN-DOPO/OMMT composites, suggesting a more effective network structure. In addition, the tensile strength, flexural properties and impact strength of the PP/PN-DOPO/OMMT composites actually increased for a good dispersion effect. Combined with the char layer analysis, the introduction of OMMT promoted more continuous and compact structural layers containing an aluminium–silicon barrier and phosphorus-containing carbonaceous char in the condensed phase. OMMT can improve the flame retardancy, thermal stability and mechanical properties of PP, and, thus, PN-DOPO/OMMT blends can serve as an efficient synergistic system for flame-retarded PP composites.

To improve the poor impact toughness of polypropylene (PP), organo-sepiolite (O-Sep) filled 80/20 (w/w) polypropylene/poly(acrylonitrile-butadiene-styrene) (PP/ABS) nanocomposites were fabricated. The contents of O-Sep were correlated with the morphological, mechanical, and rheological behavior of PP/ABS/O-Sep blends. Scanning electron microscopy (SEM) was applied to study the morphology and thermogravimetric analysis (TGA) was applied to study the thermal stability. Differential scanning calorimetry (DSC) and X-ray diffraction (XRD) were applied to study the crystallinity. The obtained results show that O-Sep enhanced the dispersion of ABS in the PP matrix and increased the crystallinity of blends. The rheological results show that O-Sep could increase the viscosity, storage modulus, and loss modulus of blends. Moreover, the mechanical behavior shows that O-Sep (at proper content) simultaneously increased the tensile modulus, flexural modulus, and impact strength of PP/ABS/O-Sep blends.

Polymer blending has been widely used to fabricate polymeric films in the last decade due to its superior properties to a single component. In this study, an aluminum phosphate-coated halloysite nanotube (HNTs@AlPO₄) was fabricated using a one-pot heterogeneous precipitation method, organically modified HNTs@AlPO₄ (o-HNTs@AlPO₄) was used to improve the performance of polyethylene oxide/poly(butylene adipate-co-terephthalate) (PEO/PBAT) blends, and the mechanical and rheological properties of the PEO/PBAT/o-HNTs@AlPO₄ films were systematically discussed. According to our results, there is an optimal addition for adequate AlPO₄ nanoparticle dispersion and coating on the surface of HNTs, and organic modification could improve the interfacial compatibility of HNTs@AlPO₄ and the polymeric matrix. Moreover, o-HNTs@AlPO₄ may serve as a compatibilizer between PEO and PBAT, and PEO/PBAT/o-HNTs@AlPO₄ films have better mechanical and rheological properties than the PEO/PBAT blends without the o-HNTs@AlPO₄ component.

Incorporating a 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide-based derivative (1,4-bis(diphenoxyphosphoryl)piperazine, DIDOPO) in combination with modified calcium sulfate whiskers (MCSWs) improved the flame retardancy, thermal stability, and rheological properties of a polyethylene oxide (PEO) composite. The synergistic flame-retardant effect of DIDOPO and MCSW on the PEO system was investigated. After introducing 5 wt.% MCSW and 10 wt.% DIDOPO into PEO, the UL-94 rating of the composite reached V-0, and the limiting oxygen index was increased to 26.5%. Additionally, the peak and average heat release rates and total heat release of the PEO/10% DIDOPO/5% MCSW composite decreased by 38.9%, 22%, and 20.07%, respectively. The results of a thermogravimetric analysis (TGA) revealed that PEO/10% DIDOPO/5% MCSW displayed an improved initial thermal stability and rate of char formation compared to those of the PEO matrix. The results of TGA/Fourier transform infrared analysis indicated that the composites exhibited phosphorus-containing groups during thermal degradation, based on the characteristic absorption peaks, and increased amounts of gas-phase volatiles. The morphologies and structures of the residues indicated that the PEO/10% DIDOPO/5% MCSW blend was less stable than PEO during combustion. The MCSW mixture formed a denser, more continuous carbon layer on the composite surface during combustion. The rheological behavior indicated that the high complex viscosity and moduli of PEO/10% DIDOPO/5% MCSW promoted the cross-linking network structure of the condensed phase during combustion. MCSW exhibited an excellent flame retardancy and improved thermal stability, which are potentially promising for use in fire safety applications.

A 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO)-based derivative (PN-DOPO) combined with aluminium phosphates-coated sepiolite (Sep@AlPO₄) was used to improve the flame retardance, thermal stability and mechanical performances of poly (ethylene oxide) (PEO)/poly (butylene adipate-co-terephthalate) (PBAT) blends. The synergistic effects of PN-DOPO and Sep@AlPO₄ on flame-retarded PEO/PBAT composites were systematically discussed. Results indicated that introducing 5 wt% Sep@AlPO₄ with 10 wt% PN-DOPO into PEO/PBAT achieved a V-1 rating for the UL-94 test and increased the limiting oxygen index value to 23.7%. Moreover, the peak heat release rate (p-HRR), average HRR and total heat release values of PEO/PBAT/PN10%/Sep5% composites decreased by 35.6%, 11.0% and 23.0% compared with those of PEO/PBAT, respectively. Thermogravimetric analysis (TGA) results confirmed that PN-DOPO/Sep@AlPO₄ enhanced the initial thermal stability and char yield of PEO/PBAT matrix, and TGA/Fourier transform infrared spectrometry results revealed that the composites exhibited the characteristic absorption peaks of phosphorous-containing groups and an increase in gas-phase volatiles during thermal degradation. The morphological structures of the residues indicated that PN-DOPO and Sep@AlPO₄ mixtures produced a more dense and continuous char layer on the composite surface during burning. Rheological behaviour revealed that higher complex viscosity and modulus values of PEO/PBAT/PN-DOPO/Sep@AlPO₄ sample could also promote the crosslinking network structure of condensed phases during combustion. Furthermore, the PEO/PBAT/PN-DOPO/Sep@AlPO₄ composites exhibited superior elongation at break and flexural performance than the PEO/PBAT system. All results demonstrated that the PEO/PBAT system modified with PN-DOPO/Sep@AlPO₄ showed remarkable flame retardance, and improved thermal stability and mechanical properties, indicating its potential application in areas requiring fire safety.

The morphology and composition of inorganic particles play a vital role in controlling the flame-retardant characteristics of polymers. Halogen-free flame-retardant polymers have also become a current research hotspot. Boron nitride (BN), phytic acid (PA), and chitosan (CS), a natural polysaccharide with a nitrogen content of approximately 6.8–7.5%, show great promise as flame retardants owing to their high thermal stability, P-based flame retardancy, and natural polysaccharide properties, respectively. In this study, BN (BN@PA-CS) particles coated with PA and CS were designed and prepared via a facile modification strategy. The effect of BN@PA-CS on the mechanical and flame-retardant properties of polyvinylidene fluoride (PVDF) was further investigated, and it was found that both characteristics were improved. Compared to pure PVDF, the PVDF composite films exhibited a significantly lower peak heat release rate and total heat release. With a BN@PA-CS content of 20%, the peak was the lowest at 18.25 W/g, corresponding to a decrease of 77.83%. This phenomenon may be attributed to the synergistic effect of the BN nanosheets and PA-CS in the BN@PA-CS particles. This work describes a facile and effective method of modifying the morphology and composition of inorganic particles, thereby controlling the properties of polymers, and provides a new approach to improving the safety of PVDF battery separators.