Effects of organo-clay and sodium dodecyl sulfonate intercalated layered double hydroxide on thermal and flame behaviour of intumescent flame retarded polypropylene

The thermal and flame performances of intumescent flame retarded polypropylene (PP/IFR) composites with organically modified clay or sodium dodecyl sulfonate intercalated layered double hydroxide (SDS-LDH) were studied. The organo-clay particles were partially exfoliated in the PP matrix while, intercalation and aggregation was obtained for SDS-LDH. Incorporation of SDS-LDH improved the thermal stability and flame retardancy of the intumescent flame retarded PP composite in the early stage of heating and combustion; while the effects of organo-clay came into play in the middle-later stage. Differences in degradation pathway of clay and LDH were responsible for the above phenomenon which bore important implication for the barrier mechanism. The introduction of organo-clay into PP/IFR not only increased the char residue, but also formed compact and folded morphology of char residue which provided more effective protect for underlying materials against heat and oxygen relative to LDH thus, improved the flame retardancy of intumescent flame retarded PP samples more efficiently. (C) 2009 Elsevier Ltd. All rights reserved.