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A novel and environmentally friendly lignin-based surfactant sodium lignosulfonate (SLS) modified layered double hydroxide (LDH) flame retardant (LDH-LS) was fabricated via co-precipitation method, and subsequently incorporated into polypropylene (PP) matrix to obtain the PP and LDH-LS composites (PP/LDH-LS) by melt blending method. The XRD, FT-IR and XPS results indicated that SLS had successfully modified LDH by adsorbing on the surface of the LDH nanosheet. The WCA and SEM results revealed that the hydrophobic property of LDH-LS had been evidently improved, and it displayed a more homogeneous dispersion than virgin LDH in the PP matrix. Furthermore, cone calorimetry tests (CCT) illustrated that the peak heat release rate (PHRR), total heat release (THR), and total smoke release (TSR) of PP/LDH-LS composites exhibited declines of 62.9%, 25.1%, and 43.3% compared with those of Neat PP, respectively. Besides, the PP/LDH-LS achieved a LOI value of 29.4% and a UL-94 V-0 rating, whereas the PP/LDH showed only a LOI value of 25.2% and a UL-94 V-2 rating at 20 wt% loading. These improvements of flame retardant properties can be attributed to that the well-dispersed LDH-LS and synergistic flame retardancy between LDH and SLS. [ABSTRACT FROM AUTHOR]

Due to the inherent defect of flammability of polypropylene (PP), a novel and highly efficient carbon microspheres@layered double hydroxides@copper lignosulfonate (CMSs@LDHs@CLS) flame retardant was designed and prepared, which was attributed to the strong electrostatic interaction between carbon microspheres (CMSs), layered double hydroxides (LDHs) and lignosulfonate as well as the chelation effect of lignosulfonate on copper ions, and then it was incorporated into the PP matrix. Significantly, CMSs@LDHs@CLS not only observably improved its dispersibility in PP matrix, but also simultaneously achieved excellent flame retardant properties for composites. With the addition of 20.0 % CMSs@LDHs@CLS, the limit oxygen index of CMSs@LDHs@CLS and PP composites (PP/CMSs@LDHs@CLS) reached 29.3 % and achieved the UL-94 V-0 rating. Cone calorimeter tests indicated that the peak heat release rate, total heat release and total smoke production of PP/CMSs@LDHs@CLS composites exhibited declines of 28.8 %, 29.2 % and 11.5 %, respectively, compared with those of PP/CMSs@LDHs composites. These advancements were attributed to the better dispersibility of CMSs@LDHs@CLS in PP matrix and illustrated that CMSs@LDHs@CLS observably reduced fire hazards of PP. The flame retardant property of CMSs@LDHs@CLS might relate to condensed phase flame retardant effect of char layer and catalytic charring of copper oxides. [ABSTRACT FROM AUTHOR]