The incorporation of large loading of flame retardants generally
causes embrittlement of materials. However, most of the rubbers and
thermoplastic elastomers are flammable. Therefore, preparation of
a flame retardant with potential toughening characteristics is urgently
required for preparing materials with both good flame retardancy and
toughness. The objective of the present work was to prepare a macromolecular
flame retardant with good flexibility, that is, 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide
(DOPO)-modified epoxidized polybutadiene (EPB–DOPO) via a creative
approach of two-step reactions. First, polybutadiene (PB) was partially
epoxidized to generate EPB; second, the reactive flame retardant DOPO
reacted with epoxy groups to generate EPB–DOPO. EPB–DOPO
with three epoxidation degrees was prepared: EPB5%–DOPO, EPB10%–DOPO,
and EPB15%–DOPO. The chemical structure of EPB–DOPO
was confirmed with proton nuclear magnetic resonance (1H NMR) and Fourier transform infrared (FTIR) spectra. Thermogravimetric
analysis (TGA) showed that EPB–DOPO had good thermal stability.
EPB10%–DOPO and EPB15%–DOPO passed the UL-94 V-2 and
V-0 rating, respectively, and the gas-phase flame retardation mechanism
was deduced. The glass transition temperature (T
g) of EPB–DOPO prepared in this study was below −20
°C. Due to little char formation, EPB10%–DOPO and EPB15%–DOPO
showed good resilience even after flame ignition. This study has provided
a creative strategy to prepare a macromolecular flame retardant with
good flexibility.