Effect of foaming behavior of polypropylene foams on flame retardant properties under different weight reduction methods

Abstract

AbstractIn previous studies, the effect of cell structures of polypropylene (PP) foam materials on flammability behavior had been largely overlooked. In this work, ammonium polyphosphate and pentaerythritol were used as intumescent flame retardants (IFR) for PP, and then the PP‐IFR flame retardant foams were prepared by using injection foaming technology with two different weight reduction methods (same mold volume before foaming and after foaming). The results showed that the average cell size of all the PP‐IFR flame retardant foams in the 10% to 30% weight reduction was less than 100 μm. The PP‐IFR flame retardant foams with an average cell diameter of 26.22 μm and cell density of 7.88 × 106 cells/cm3 had the best limiting oxygen index (LOI) of 27.9%. In addition, the PP‐IFR flame retardant foams with better foaming quality had a higher LOI and a denser foam carbon layer whatever the weight reduction methods, resulting in better flame retardant properties. The escape of gases from the foamed and un‐foamed areas not only reduced the concentration of flammable gases but also led to the collapse and rupture of the foam carbon layer during the combustion process. Hence, it provides guidance for preparing PP foam materials with excellent flame retardancy.