Synergistic effects of aluminum hydroxide on improving the flame retardancy and smoke suppression properties of transparent intumescent fire-retardant coatings

A series of novel aluminum phosphate ester (APEA) flame retardants were synthesized by the salification of cyclic phosphate ester acid (PEA) with different mass ratios of aluminum hydroxide (ATH) and thoroughly characterized by Fourier transform infrared (FTIR) spectroscopy and ¹H nuclear magnetic resonance spectroscopy. The PEA and APEAs were thoroughly mixed with melamine formaldehyde resin to produce five kinds of transparent fire-retardant coatings. The synergistic effects of ATH on the thermal stability, flame retardancy, and smoke suppression properties of the coatings were investigated by different analytical instruments. The results show that the incorporation of ATH greatly decreases the weight loss, char index, flame spread rating, heat release rate, total heat release, smoke production rate, total smoke release and specific optical density in the coatings applied to plywood boards, which is ascribed to a more compact and intumescent char formed during burning, as determined from digital photographs and scanning electron microscopy images. The synergistic effects of ATH in the coatings depend on the content of ATH, and an excessive amount of ATH diminishes the synergistic effects on the flame retardancy and smoke suppression properties based on fire protection tests and cone calorimeter test. Thermo-gravimetric analysis reveals that the thermal stability and char-forming ability of the coatings gradually improve with increasing loading of ATH. FTIR analysis demonstrates that the incorporation of ATH forms a more phosphorus-rich crosslinked char and aromatic char during burning, thus effectively reducing the mass loss, heat release, and smoke production and exhibiting excellent synergistic flame retardant and smoke suppression effects in the coatings.