PP-MIPS

An innovative phosphorus rich intumescent oligomer enabling commercially competitive high performance halogen free fire protection of polypropylene

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 Obiettivo del progetto (Objective)

'Offering good performance at low cost, polypropylene (PP) is a popular commodity plastic within many market sectors. However, due to its high flammability and low charring nature, PP is difficult to fire protected. Whist brominated flame retardants (FRs) are able to achieve excellent FR performance at moderate cost and with little impact on polymer properties, they release toxic and corrosive smoke during fire, are potentially harmful to the environment and restrict PP recyclability. There is thus increased legislative and political pressure for a reduction in halogen FR use. Existing halogen free PP flame retardants are based on low performance & low cost mineral FR additives or high performance & high cost intumescent systems, both requiring high to moderate loadings thereby impacting on polymer properties and restricting use for high performance applications.

‘Mixed intumescent polymeric salts’ (MIPS) are a novel cost efficient high performance intumescent FR additive. Utilising phosphorous rich oligomers synthesised from readily available raw materials, the MIPS chemistry integrates the essential components for intumescence within one molecule, locked in a reaction state immediately preceding intumescence, thereby enabling: - High performance at reduced loading: Rapid and efficient intumescence at low temperatures achieving enhanced flame retardancy and smoke suppression; - Cost Competitiveness: Low cost additive manufacture combined with reduced loading enabling additive package pricing in-line with halogen based systems; - Superior physical and mechanical properties: non-particulate and oligomeric nature (melt blendable) and reduced loading levels, achieving significantly reduced impact on base polymer properties;

PP-MIPS will further advance ‘MIPS’ as an intumescent fire protection chemistry for PP, targeting commercial competitiveness with halogen based FR systems and enabling their replacement for high performance applications. The PP-MIPS compounds will be demonstrated for two high profile case study applications: 1) halogen free UL94-V2 rated PP fibres; and 2) NFPA-262 rated cable insulation jackets. Such applications are currently only possible using halogenated polymer compounds. PP-MIPS will generate ~€50 million business growth for its SMEs within a 3 year period.'

Introduzione (Teaser)

Polypropylene (PP) is used in a myriad of products, including packaging, rugs, furniture and automotive components, but it is highly flammable. EU-funded scientists laid the groundwork for development of eco-friendly fire protection compatible with stringent requirements.

Descrizione progetto (Article)

Cost-effective and high-performance PP is highly flammable yet difficult to protect against fire. Conventional halogenated flame retardants (treated with chemicals in the halogen group, including bromine) serve their designated function well without affecting polymer properties. However, they release toxic and corrosive smoke when heated excessively. Currently available halogen-free products, while effective against fire, require high loadings that have a detrimental effect on polymer properties.

Mixed intumescent polymeric salts (MIPS) are an inexpensive yet high-performance alternative. Intumescent chemical systems expand into thick insulating chars when exposed to high temperatures. They provide protection to underlying systems both through endothermal chemical reactions (that absorb heat) and by providing a physical barrier to heat transfer. Scientists have advanced the state of MIPS for PP fire protection through work on the project http://www.pp-mips.eu/ (PP-MIPS).

They focused on two high-performance applications that are currently only possible using halogenated polymers. These were PP fibres meeting protective clothing standards and PP cable insulation jackets achieving the strictest international performance standards.

MIPS chemistry based on easily synthesised phosphorous-rich compounds combines the essential reaction components in a single molecule one step away from intumescence. Scientists focused on formulations with higher activation temperature and greater resistance to decomposition.

Work included scaling up production of MIPS to supply the quantities needed for testing. Investigators also conducted numerous processing trials to assess whether or not the MIPS affected polymer processing capabilities or mechanical properties of components.

The vast amount of knowledge accumulated within the scope of the PP-MIPS project has brought eco-friendly fire protection for PP to a mature stage for final optimisation. The rival to conventional halogenated plastics is sure to make a splash given the pressing need to find a replacement fulfilling stricter regulations.