In this work, an alternative flame-retardant filler based on phosphate-and urea-grafted bamboo charcoal (BC-m) at 10−30 wt % addition was aimed at improving the flame retardancy of polylactic acid (PLA) composites. The filler caused only a small reduction in strength properties but a slight increase in the modulus of elasticity of PLA composites. BC-m significantly improved the flame-retardant performance compared with pure BC. The limiting oxygen index (LOI) was 28.0 vol % when 10 wt % of BC-m was added, and 32.1 vol % for 30 wt % addition, which was much greater than the value of 22.5 vol % for 30 wt % pure BC. Unlike pure BC, adding BC-m at 20 wt % or more gave a UL-94 vertical flame test rating of V-0 with significantly reduced melt dripping. The peak heat release rate (pHRR) and total heat release (THR) of BC-m/PLA composites decreased by more than 50% compared with pure PLA, and the values for 20% BC-m were significantly less than that for 25% BC addition. The grafted biochar-based system provides an effective flame retardancy effect by a condensed-phase protective barrier through the rapid formation of a dense, honeycomb-like cross-linked carbonized char layer. The results suggest a promising route to enhancing the flame-retardant properties of biodegradable polymer composites using nontoxic, more environmentally friendly grafted biochar.

A cooperative flame-retardant system based on natural intumescent-grafted bamboo charcoal (BC) and chitosan (CS) was developed for polylactic acid (PLA) with improved flame retardancy and minimal decline in strength properties. Chitosan (CS) as an adhesion promoter improved the interfacial compatibility between graft-modified bamboo charcoal (BC-m) and PLA leading to enhanced tensile properties by 11.11% and 8.42%, respectively for tensile strength and modulus. At 3 wt.% CS and 30 wt.% BC-m, the crystallinity of the composite increased to 38.92%, or 43 times that of pure PLA (0.9%). CS promotes the reorganization of the internal crystal structure. Thermogravimetric analysis showed significantly improved material retention of PLA composites in nitrogen and air atmosphere. Residue rate for 5 wt.% CS and 30 wt.% BC-m was 29.42% which is 55.1% higher than the theoretical value of 18.97%. Flammability tests (limiting oxygen index-LOI and UL-94) indicated significantly improved flame retardancy and evidence of cooperation between CS and BC-m, with calculated cooperative effectiveness index(Ce) >1. From CONE tests, the peak heat release rate (pHRR) and total heat release (THR) were reduced by 26.9% and 30.5%, respectively, for 3% CS + 20% BC-m in PLA compared with adding 20% BC-m alone. Analysis of carbon residue morphology, chemical elements and structure suggest CS and BC-m form a more stable char containing pyrophosphate. This char provides heat insulation to inhibit complete polymer pyrolysis, resulting in improved flame retardancy of PLA composites. Optimal mix may be recommended at 20% BC-m + 3% CS to balance compatibility, composite strength properties and flame retardance.

Plastics and foaming agents are often used to prepare large-size and low-density bamboo charcoal (BC) based composites. In this study, a plastic-free and foaming agent-free BC based composite was prepared by substituting sodium silicate (SS) for plastics. The effect of both the BC particle sizes and the usage amount of SS on the mechanical and adsorptive properties of the BC/SS composites were investigated. The experimental results show that when the BC particle size is 270 μm and the mass ratio of BC to SS is equal to 10:5, the BC/SS composite has the optimal foaming effect and best comprehensive properties. In addition, the foaming pores of the composite are caused by water vapor, which has difficulty escaping the BC because of the blockage of SS during the hot pressing process. In the BC/SS composite (10:5), the static bending intensity and the compressive strength reach respectively 6.13 MPa and 5.5 MPa, and the average pore size and porosity are 557.85 nm and 52.03%, respectively. In addition, its formaldehyde adsorptionrate reaches 21.6%. In view of good mechanical properties, formaldehyde adsorption, and environmentally friendly performance, the BC/SS composite has a great potential as a core layer of interior building materials.