Fire hazards related to polymer-based thermally conductive composites (PTCs) used in electronic equipment are a significant, but often neglected, risk. Here, we offer a solution by incorporating flame retardant-functionalized graphene (PFR-fRGO) into PTCs using a procedure that improves both their flame resistance and thermal conductivity. Briefly, PFR-fRGO was prepared by covalently grafting a polyphosphoramide oligomer (PDMPD) onto the surface of graphene, which was then introduced in situ into epoxy resin/Al2O3 (EP/Al2O3) composites. As expected, the incorporation of PFR-fRGO not only increased the thermal conduction paths by weakening the settlement of microparticles, but also reduced the interfacial thermal resistance by enhancing interfacial interactions, both of which resulted in an enhancement of the thermal conductivity of the ternary composites. The resultant EP/Al2O3/PFR-fRGO composite exhibited a superior flame retarding ability with dramatic decreases being seen in the high peak heat release rate (PHRR), the total heat release (THR) and the total smoke production (TSP), i.e. 53%, 37% and 57%, respectively, when compared to pure epoxy resin. Additionally, a synergistic flame retarding effect was found in the ternary composite compared to the EP/PFR-fRGO and EP/Al2O3 composites. The remarkable enhancement in flame retardancy was mainly attributed to the catalytic charring effect of PFR-fRGO and the template effect of Al2O3, both of which resulted in the formation of a high strength, thermally stable protective layer in the condensed phase that is able to retard the permeation of heat and volatile degradation products during combustion, slow down the heat release rate and protect the underlying polymer.

As alternative flame-retardant additive for polymers, reduced graphene oxide (RGO) is often limited by its poor interfacial compatibility with matrix. In this work, a new flame retardant, containing phosphorous, nitrogen and silicon elements was used to functionalize RGO. The wrapped flame retardant chains induced the improvement in the dispersion and compatibility of RGO in epoxy (EP) matrix. As a result, the mechanical, thermal and flame retardant properties of EP-based composites were significantly improved by adding flame retardant-functionalized RGO. The peak heat release rate, total heat release and total smoke production reduced by 34%, 14% and 30%, respectively, compared to neat resin. Based the char analyses, the enhancement in flame retardancy is attributed to the outstanding char layers with high strength and thermal stability resulting from the template effect of graphene, the charring effect of phosphorus and nitrogen elements and the enhancing effect of silicon element in grafted flame retardant chains.

Fire hazards related to polymer-based thermally conductive composites (PTCs) used in electronic equipment are a significant, but often neglected, risk. Here, we offer a solution by incorporating flame retardant-functionalized graphene (PFR-fRGO) into PTCs using a procedure that improves both their flame resistance and thermal conductivity. Briefly, PFR-fRGO was prepared by covalently grafting a polyphosphoramide oligomer (PDMPD) onto the surface of graphene, which was then introduced in situ into epoxy resin/Al2O3 (EP/Al2O3) composites. As expected, the incorporation of PFR-fRGO not only increased the thermal conduction paths by weakening the settlement of microparticles, but also reduced the interfacial thermal resistance by enhancing interfacial interactions, both of which resulted in an enhancement of the thermal conductivity of the ternary composites. The resultant EP/Al2O3/PFR-fRGO composite exhibited a superior flame retarding ability with dramatic decreases being seen in the high peak heat release rate (PHRR), the total heat release (THR) and the total smoke production (TSP), i.e. 53%, 37% and 57%, respectively, when compared to pure epoxy resin. Additionally, a synergistic flame retarding effect was found in the ternary composite compared to the EP/PFR-fRGO and EP/Al2O3 composites. The remarkable enhancement in flame retardancy was mainly attributed to the catalytic charring effect of PFR-fRGO and the template effect of Al2O3, both of which resulted in the formation of a high strength, thermally stable protective layer in the condensed phase that is able to retard the permeation of heat and volatile degradation products during combustion, slow down the heat release rate and protect the underlying polymer.