Eco‐friendly flame retardant epoxy nanocomposites based on polyphosphonate and halloysite nanotubes

The preparation of a novel polyphosphonate (PSFR) is described here, starting from phenylphosphonic dichloride and an equimolecular mixture containing equal amounts of two bisphenols, namely 4,4′‐dihydroxydiphenyl sulfone and 2‐(6‐oxido‐6H‐dibenzooxaphosphorin‐6‐yl)‐1,4‐benzenediol, following the polycondensation reaction in solution. Then, new environmental‐friendly nanocomposites having improved flame retardancy have been prepared by incorporating PSFR and halloysite nanotubes (HNTs) into epoxy resin. The effect of PSFR and HNTs contents on the chemical and physical characteristics of epoxy nanocomposites was investigated. The success of the reactions was monitored by infrared spectroscopy (FTIR) while microscopic related techniques (SEM) gave information on the morphology of the products. The thermosets exhibit glass transition temperatures in the range of 62.4–97.1°C and thermal decomposition temperatures in the interval of 296–359°C. The appearance of the char residues obtained by pyrolysis was studied by SEM measurements. The flammability behavior has been studied by microscale combustion calorimetry (MCC) tests. A considerable improvement in the flame retardancy of the thermosets was obtained by simultaneous incorporation of HNTs (10 wt%) and PSFR (equivalent of 1 wt% P) into epoxy resin. Graphical representation for the synthetic pathway of epoxy nanocomposites and heat release rates versus temperature (left) and time (right) for the samples