Processing and Upscaling of Fire-Resistant Nano-Filled Thermosetting Polyester Resin

The ability of well-dispersed organomodified clays to enhance the fire-retardency of thermoplastic polymers is well established, but thermoset polyester has received relatively little attention. In a recent collaborative project, the fire retardency of polyester resin was dramatically improved on a lab scale by adding small amounts of organomodified clay, along with significantly reduced amounts of other non-halogen, fire retardant additives. 

However, significant further work is required to scale up production and assess the health and environmental impacts. Polyfire will develop and upscale techniques for processing halogen-free, fire retardant nanocomposites and coatings based on unsaturated polyester resins and clays. These materials will improve public safety and environmental impact by eliminating halogenated fire retardents which produce toxic combustion products. Challenging associated with optimising the dispersion of the modified clays in the resins will be addressed using novel mixing techniques to enable industrial scale production of the nano-filled polyester. 

The project will develop turn-key solutions for easy integration into industrial SMEs. Nanocomposites will be produced and subjected to stringent tests. The technology will be demonstrated by producing three large scale case study parts from construction, rail and marine sectors. Comprehensive health and environmental impact assessments will be conducted.

Figure 1. A material developed in Polyfire is subjected to the flooring radiant panel test (EN ISO 9239-1).