Zinc borate mother solution is cycled to prepare 2ZnO·3B 2 O 3 ·7H 2 O, 3ZnO·5B 2 O 3 ·14H 2 O, and 4ZnO·B 2 O 3 ·H 2 O based on the properties of borate depolymerization. The results show uniform quadrilateral-prism-like and octahedron-like 2ZnO·3B 2 O 3 ·7H 2 O are synthesized at different temperatures. Flake-like 3ZnO·5B 2 O 3 ·14H 2 O is fabricated as reaction time prolonging, and 2ZnO·3B 2 O 3 ·7H 2 O changed into 3ZnO·5B 2 O 3 ·14H 2 O spontaneously. Meanwhile, resulting 2ZnO·3B 2 O 3 ·7H 2 O is investigated to fabricate high aspect ratio of 4ZnO·B 2 O 3 ·H 2 O whisker. Impressively, uniform 4ZnO·B 2 O 3 ·H 2 O whisker can be resynthesized by the filtrates of 2ZnO·3B 2 O 3 ·7H 2 O and 3ZnO·5B 2 O 3 ·14H 2 O via the zero-waste technology.
In this work, the influences of 4ZnO·B 2 O 3 ·H 2 O zinc borate (ZB) whisker based intumescent flame retardant (IFR) containing ammonium polyphosphate and dipentaerythritol on the mechanical, flame retardant and smoke suppression properties of polypropylene (PP) composites were characterized by the universal testing machine, UL-94, limiting oxygen index (LOI), and cone calorimeter tests, respectively. The results indicate that only 1 phr of ZB could effectively improve the LOI value and slow down the burning rate of PP composite. The peak heat release rate, average of HRR, total heat release, peak smoke production rate, and total smoke production values are all decreased from 413.8 kW/m 2 , 166.3 kW/m 2 , 82.3 MJ/m 2 , 0.0995 m 2 /s, and 17.9 m 2 for PPc/20IFR composite to 267.8 kW/m 2 , 128.3 kW/m 2 , 66.8 MJ/m 2 , 0.0478 m 2 /s, and 12.6 m 2 for PPc/20IFR/1ZB composite, respectively. The scanning electron microscopy images, energy dispersive spectrometry, and Raman spectra of char residue reveal that ZB is helpful to form a compact and graphitized intumescent char residue so that the heat diffusion and oxygen transmission are greatly hindered. The thermogravimetry analysis-fourier transform infrared spectroscopy (TGA-FTIR) results show that less combustible volatiles and more H 2 O vapor are generated with the appearance of ZB. Hence, the combustion mechanism in gas phase is suppressed.