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Queen Mary University of LondonQueen Mary University of London
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School of Engineering and Materials Science
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PhD Thesis: Development and Characterisation of Flame Retardant Nanoparticulate Bio-based Polymer Composites

Author: HAPUARACHCHI, T Dhanushka

Year: 2010

Supervisor(s): Ton Peijs

Traditional methods to improve the flame retardancy of polymeric material involve the use of the micron sized inorganic fillers like ammonium polyphosphate (APP) or aluminium trihydroxide (ATH). Imparting flame retardancy with these inorganic fillers is possible but only with relatively high loadings which can be as much as 50 wt.%. This causes detrimental effects to the mechanical properties of the composite and embrittlement. Applying nanofillers can achieve similar if not better flame retarding performances to their micron sized counterparts but at much lower loading levels (<10 wt.%), thus preserving better the characteristics of the unfilled polymer such as good flow, toughness, surface finish and low density. The objectives of this research will be to develop a natural fibre polymer composite utilising sustainable bulk materials and improved recyclability. The other being to impart flame retardance to the final composite without using high inorganic filler levels. This will be achieved by a development programme of materials selections and using various experimental techniques including the cone calorimeter and the recently developed microcalorimeter. After a comprehensive literature survey (Chapter 2), the experimental part of the thesis starts with a feasibility study of a flame retardant natural reinforced fibre sheet moulding compound (SMC) (Chapter 3). This work demonstrated that with a suitable flame retardant the peak heat release rate can be reduced. Chapter 4 deals with further improving the flame retardancy of the previously used unsaturated polyester resin. The aim is to study any synergistic behaviour by using aluminium trihydroxide in conjunction with ammonium polyphosphate whilst testing in the cone calorimeter. In Chapter 5, nanofillers are used to replace traditional micron sized fillers. In unsaturated polyester, multiwall carbon nanotubes and sepiolite nanoclay are used together to create a ternary polymer nanocomposite. The microcalorimeter was employed for screening of the heat release capacity (HRC). This work showed that the ternary nanocomposite showed synergistic behaviour with regards to significantly reducing the HRC. The same nanofillers were utilised in Chapters 6 and 7 but this time in combination with a thermoplastic (polypropylene) and bio-derived polymer (polylactic acid), respectively. In both systems an improved flame retardancy behavior was achieved whist meeting the recyclability objective. Chapter 8 attempts to show how the optimised natural fibre composite would behaviour in a large scale fire test. The ConeTools software package was used to simulate the single burning item test (SBI) and to classify the end product. This is a necessity with regards to commercializing the product for consumer usage. Finally, Chapter 9 is a summary of the work carried out in this research as well as possible future work that should be conducted.

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