The synthesis and characterization of a DOPO derivative bearing an active terminal epoxy group: e-DOPO and its application in rigid polyurethane foam

DOPO and its derivatives are excellent phosphorus-based flame retardants, which are applied to a series of polymer materials. In this article, a DOPO derivative bearing an active terminal epoxy group was synthesized using a non-solvent method. Fourier transform infrared spectroscopy, nuclear magnetic resonance, mass spectrometry, ultra-performance liquid chromatography, differential scanning calorimetry, thermogravimetric analysis, and viscosity measurements were performed to determine its molecular structure, purity, thermal performance, and fluidity. A possible fragmentation mechanism of the as-prepared DOPO derivative was analyzed using electron ionization mass spectrometer. All the results indicate that the synthesis was successful and the product had satisfactory purity and its initial decomposition temperature (T_5%) under nitrogen and air atmosphere was 246°C and 240°C, respectively. Then, as a comparison with dimethyl methyl phosphonate, triethyl phosphate, and DOPO, e-DOPO was applied to a rigid polyurethane foam to investigate its effect on the flame retardancy, thermal stability, and cell morphology of polyurethane foam by limiting oxygen index, cone calorimetry, thermogravimetric analysis, and scanning electron microscopy. The results indicate that e-DOPO has a greater effect than DOPO and can effectively reduce the heat release and smoke release and improve the limiting oxygen index and thermal performance of the polyurethane foam. The cell size of the sample containing e-DOPO was more uniform.