Preparation and properties of new flame retardant unsaturated polyester nanocomposites based on layered double hydroxides

The preparation of new layered double hydroxides/unsaturated polyester (LDH/UP) nanocomposites was performed and the effect of LDH on the resin properties was studied. Two different organo-LDHs have been prepared, adipate-LDH (A-LDH) and 2-methyl-2-propene-1-sulfonate-LDH (S-LDH); in order to evaluate the influence of these nanofillers, samples with two different concentrations were dispersed in the matrix. The physical, thermal, mechanical and fire reaction properties of nanocomposites were studied. Intercalated layered structures were observed for the different organo-LDH loadings (1 and 5 wt%). Mechanical properties studied under flexural tests show that incorporation of organo-LDH in the resin reduces the flexural strength of polyester resin while the flexural modulus is unchanged for the S-LDH/UP composites and increased with 1 wt% of A-LDH. Adding 1 wt% of A-LDH to the resin produces an important reduction on the flexural strength, but an increase of the flexural modulus. The study of fire reaction properties, using cone calorimeter, suggested a significant reduction in the UP flammability, by 46 and 32%, by incorporating 1 wt% of A-LDH and 5 wt% S-LDH, respectively. Mass loss curves show enhanced char formation with the different loads tested while the amount of evolved smoke remains quite unchanged.