ULTRAFIRERESISTANTTHERMOSETPOLYMERS.ppt

ULTRA FIRE RESISTANTTHERMOSET POLYMERS Richard E. Lyon Fire Research Program Fire Safety Section AAR-440FEDERAL AVIATION ADMINISTRATION W.J. Hughes Technical Center Atlantic City International Airport, NJ 08405 ULTRA FIRE RESISTANT THERMOSET POLYMERS * * OUTLINE OF TALK FAA Fire Resistant Materials Program Background of Bisphenol-C Polymers New Bisphenol-C Polymers Fire Flammability Results Conclusions FAA PROGRAM OBJECTIVE: PROGRAM DELIVERABLES A VERSATILE BUILDING BLOCK IS NEEDED Thermoplastics Thermosets BACKGROUND: Bisphenol-C Polymers 1874: Chloral-phenol condensation reaction product (I) first reported. 1874: Dehydrochlorination to 1,1-dichloro, 2,2-bis(4-hydroxyphenyl) ethylene (bisphenol-C, BPC) first reported. 1964: Polycarbonate from BPC first reported. 1965: “Self-Extinguishing Epoxies” from BPC first reported in Poland. BACKGROUND: Bisphenol-C Polymers GE begins research to obtain non-burning (XB) plastics. Investigates bisphenol-C, etherimide, and acetylenic polymers. 1970’s: BACKGROUND: Bisphenol-C Polymers ? Acetylenic groups increase char yield in flame. ? Too many acetylenes increase flammability (decrease LOI) C.B. Quinn, 1967 1970’s: BACKGROUND: Bisphenol-C Polymers GE develops and patents industrial process chemistry to make BPC-polycarbonate (XB-1) and polyetherimide (XB-2). GE downselects to XB-2 (ULTEM?) because of fire (UL) and high temperature (TEM) capability. XB-2 XB-1 1980’s – 1990’s: Research in chloral condensation polymers continues in Poland and Russia but not in U.S.A. ? Fire testing limited to flame tests (flammability). ? High LOI (50-60) and “self-extinguishing” behavior attributed to chlorine content. ? No commercial activity. BACKGROUND: Bisphenol-C Polymers 1994: Comprehensive review: Condensation Polymers Based on Chloral And Its Derivatives, A.L. Rusanov, Progress In Polymer Science, Vol. 19, pp. 589- 662 (1994) BACKGROUND: Flaming Heat Release Rate Measured 1997: FAA measu