Development of Silylated Lignin-Based Intumescent Flame Retardants for Biodegradable Plastics

The global market for flame-retardant materials is expected to grow steadily, from USD 7.0 billion in 2022 to USD 16.6 billion in 2030, driven by increasing demand for environment-friendly fire safety solutions in transportation, construction, and electronics. Polylactic acid (PLA), a biodegradable polymer which possesses excellent mechanical properties, is increasingly being considered for future mobility applications. However, it is characterized by high heat release and toxic smoke during combustion, which are significant drawbacks. In order to address this, the chemical modification of Kraft lignin was achieved through a phenolation and subsequent silylation with tetraethoxysilane, aiming to mitigate the degradation of PLA’s mechanical properties while utilizing its inherent char-forming ability. The modified lignins were combined with ammonium polyphosphate (APP) and melt-mixed with PLA using an injection-mixing molder to prepare test specimens. Analysis by FT-IR, NMR spectroscopy, and SEM-EDS confirmed successful grafting of phenolic and silane functionalities, and thermogravimetric analysis demonstrated enhanced thermal stability of the modified lignins compared to unmodified ones. Vertical burning tests and limiting oxygen index (LOI) measurements showed that the PLA/APP/SPKL composite material achieved a V-0 UL-94 rating and 31.95% LOI, demonstrating the highest level of flame retardancy. This compares to the LOI of neat PLA, 19 to 21%. Despite the enhancement in flame retardancy to the V-0 level, the decline in tensile strength was limited, and the composite retained comparable mechanical strength to PLA-APP composites with V-2 flame retardancy. The findings indicate that the combination of phenolation and silylation of lignin with APP, a flame-retardant material, offers a viable and sustainable methodology for the fabrication of PLA composites that exhibit both flame retardancy and mechanical strength.