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In this paper, magnesium oxysulfate whiskers (MOSw) were reacted with dodecyl dihydrogen phosphate (DDP) to prepare DDP functionalized MOSw (DDPMOSw). The morphology and structure of DDPMOSw were characterized by scanning electron microscopy (SEM), transmission electron microscopy (TEM), Fourier transform infrared spectroscopy (FTIR), and X-ray photoelectron spectroscopy (XPS). Then MOSw and DDPMOSw were respectively incorporated into polypropylene (PP) to obtain hybrid composites via the melt mixing method. SEM results showed that the DDPMOSw were distributed more evenly within the PP matrix than MOSw, resulting in the improved thermal stability, nominal strain at break, and impact toughness of PP/DDPMOSw in comparison with PP/MOSw. The flammability of the composites was investigated using limiting oxygen index (LOI) and cone calorimetry (CC) tests. The results showed that the introduction of DDPMOSw into the PP matrix further increased the LOI, meanwhile, reducing the heat release rate (HRR), smoke production rate (SPR) and CO and CO2 release. SEM and energy dispersive spectroscopy (EDS) analyses of the char residues implied two reasons for the more efficient flame-retardant properties of PP/DDPMOSw than PP/MOSw: (i) DDPMOSw was more thoroughly decomposed to release more nonflammable gases and absorb more heat during the combustion process (gas-phase flame-retardant effect); (ii) DDP induced the formation of the carbonaceous residue, leading to a compact and coherent char based on MgO whiskers backbone (condensed-phase flame-retardant effect). Besides, FTIR results indicated that the phosphorous compound layer in the condensed phase also acted as a protective shield.

rsc advances

Functional group effect on flame retardancy, thermal, and mechanical properties of organophosphorus-based magnesium oxysulfate whiskers as a flame retardant in polypropylene