1 Batman University, Vocational School of Technical Sciences, Department of Chemistry and Chemical Processing Technologies, Chemistry Technology Program, Batman, Türkiye
2 Gazi University, Faculty of Technology, Department of Metallurgical and Materials Engineering, Metallurgical and Materials Engineering Division, Ankara, Türkiye
Abstract
This study investigated the effects of triphenyl phosphate (TPP) as a flame retardant and graphite (G) in nanoparticle form on the mechanical, thermal, and flammability properties of expandable polystyrene (EPS) nanocomposite foam. A batch reactor was designed and manufactured. TPP/G/PS nanocomposite beads were produced through suspension polymerization by adding styrene monomer, 20% TPP by weight, 1%, 3%, and 5% nanographite by weight, and other chemicals to the reactor. The PS beads were expanded with n-pentane to turn them into EPS beads, and the EPS beads were subjected to pre-expansion, maturation, molding, and cooling to obtain blocks. The EPS boards obtained from these blocks were exposed to tensile and flexural mechanical tests, TGA tests, UL94, LOI, and cone calorimetry flammability tests according to ASTM and ISO standards. The neat EPS foam began to degrade at 384 °C and was completely consumed. The foams containing TPP and G began to degrade at higher temperatures. In cone calorimetry, the foams containing TPP and G ignited later than the neat foam, the heat release rate decreased as added TPP and G increased, the flame height during combustion decreased as added G increased, and more smoke was produced. It was concluded that the thermal stability and flame-retardant properties of the materials increased.
KOÇYİĞİT, N., & YALÇIN , N. (2026). The Effects of Graphite and Triphenyl Phosphate on the Mechanical, Thermal Stability, and Flammability Properties of Expandable Polystyrene Foam. MAS Journal of Applied Sciences, 11(3), 571–588. https://doi.org/10.5281/zenodo.21621072
📄Almeida, F.A., Beyrichen, H., Dodamani, N., Caps, R., Müller, A., Oberhoffer, R., 2020. Thermal conductivity analysis of new sub-micron sized polystyrene foam. Journal of Cellular Plastics, 57(4): 494-515.
📄AlYousef, Z., Almobarky, M.A., Schechter, D., 2018. The effect of nanoparticle aggregation on surfactant stability. Journal of Colloid and Interface Science, 511: 365-373.
📄Attia, N.F., 2021. Sustainable and efficient flame retardant materials for achieving high fire safety for polystyrene composites. Journal of Thermal Analysis and Calorimetry, 147: 5733-5742.
📄Attia, N.F., Zayed, M., 2017. Nanoparticles decorated on resin particles and their flame retardancy behavior for polymer composites. Journal of Nanomaterials, 2017(1): 1-8.
📄Bae, M., Lee, H., Choi, G., Kang, J., 2021. An effective expanded graphite coating on polystyrene bead for improving flame retardancy, Materials, 14(21): 6729.
📄Bayramoğlu, G., Eşiyok, S., 2017. Polystrene- phosphine oxide modified clay nanocomposites. Afyon Kocatepe University Journal of Science and Engineering, 17: 440-448.
📄Campo, E.A., 2008. Thermal properties of polymeric materials. In: Campo, E.A. (Ed.), Selection of Polymeric Materials: How to Select Design Properties from Different Standards. William Andrew Publishing, Norwich, NY, pp. 103–140.
📄Dittrich, B., Wartig, K.A., Hofmann, D., Mülhaupt, R., Schartel, B., 2013. Flame retardancy through carbon nanomaterials: Carbon black, multiwall nanotubes, expanded graphite, multi-layer graphene and graphene in polypropylene. Polymer Degradation and Stability, 98(8): 1495-1505.
📄D2863-97, Standard test method for measuring the minimum oxygen concentration to support candle-like combustion of plastics.
📄D635-18, Standard test method for rate of burning and/or extent and time of burning of plastics in a horizontal position.
📄D638-14, Standard test method for tensile properties of plastics.
📄D790-15, Standard test methods for flexural properties of unreinforced and reinforced plastics and electrical insulating materials.
📄D3801-00, Standard test method for measuring the comparative burning characteristics of solid plastics in a vertical position.
📄Faniyi, I.O., Olofinjana, B., Fasakin, O., Ajenifuja, E., Alo, F.I., Eleruja, M.A., Ajayi, E.O.B., 2021. Effects of graphene oxide and reduced graphene oxide on thermal and mechanical properties of expanded polystyrene-based composites. Bulletin of Materials Science, 44(164).
📄Folorunso, O., Hamam, Y., Sadiku, R., Kupolati, W., 2024. Effects of defects on the properties of polymer nanocomposites: A brief review. Journal of Inorganic and Organometallic Polymers and Materials, 34: 5667-5690.
📄Gaidhani, A., Tribe, L., Charpentier, P., 2023. Polystyrene carbon composite foam with enhanced insulation and fire retardancy for a sustainable future: Critical review. Journal of Cellular Plastics, 59(5-6).
📄Ge, L.L., Duan, H.J., Zhang, X.G., Chen, C., Tang, J.H., Li, Z.M., 2012. Synergistic effect of ammonium polyphosphate and expandable graphite on flame-retardant properties of acrylonitrile-butadiene-styrene. Journal of Applied Polymer Science, 126(4): 1337-1343.
📄Goyal, R.K., Jagadale, P.A., Mulik, U.P., 2009. Thermal, mechanical, and dielectric properties of polystyrene/expanded graphite nanocomposites. Journal of Applied Polymer Science, 111: 2071-2077.
📄Han, Y., Wu, Y., Shen, M., Huang, X., Zhu, J.J., Zhang, X., 2013. Preparation and properties of polystyrene nanocomposites with graphite oxide and graphene as flame retardants. Journal Material Science, 48: 4214-4222.
📄Hu, L., Wang, Z., 2015. Flame retardant and mechanical properties of expanded polystyrene foams containing aluminum phosphinate and expandable graphite. Proceedings of the International Conference on Advances in Energy, Environment and Chemical Engineering. Conference Proceedings Book, 26-27 September, Atlantis Press, Changsha, China, pp. 223–226
📄Huang J., Zhao Z., Chen, T., Zhu, Y., Lv, Z., Gong, X., Niu, Y., Maa, B., 2019. Preparation of highly dispersed expandable graphite/polystyrene composite foam via suspension polymerization with enhanced fire retardation. Carbon, 146: 503-512.
📄Isah, M., Shehzad, F., Al-Harthi, M.A., 2025. Advances in graphene-based flame-retardant for polystyrene applications: Synthesis, mechanisms, and future perspectives. Polymers, 17(13): 1811.
📄International Organization for Standardization (ISO), 2002. ISO 11925-2:2002. Reaction to fire tests-ignitability of building products subjected to direct impingement of flame-Part 2: Single-flame source test. International Organization for Standardization, Geneva, Switzerland.
📄Işıtman, N.A., 2012, Flame retardancy of polymer nanocomposites. PhD Thesis, Middle East Technical University, The Graduate School of Natural and Applied Science, Ankara.
📄Jaikant, A., Goyal, S., 2021. Properties of expanded polystyrene (EPS) and its environmental effects. Advances and Applications in Mathematical Sciences, 20(10): 2151-2162.
📄Kashiwagi, T., Du, F., Douglas, J.F., Winey, K.I., Harris Jr., R.H., Shields, J.R., 2005. Nanoparticle networks reduce the flammability of polymer nanocomposites. Nature Materials, 4(12):928e33.
📄Kausar, A., Muhammad, W.U., Bakhtiar, 2015. Processing and characterization of fire-retardant modified polystyrene / functional graphite composites. Composite Interfaces, 22(6): 517–530.
📄Kausar, A., Avant-garde polymer and nano-graphite-derived nanocomposites-Versatility and implications. Journal of Carbon Research, 9(1): 13.
📄Kausar, A., Ullah, W., Muhammad, B., Siddiq, M., 2015. Influence of processing technique on the physical properties of modified polystyrene/exfoliated graphite nanocomposites. Materials and Manufacturing Processes, 30: 346-355.
📄Kaynak, C., Sipahioğlu, B.M., 2013. Effects of nanoclays on the flammability of polystyrene with triphenyl phosphate-based flame retardants. Journal of Fire Sciences, 31: 339-355.
📄Koçyiğit, N., 2022, Improving flame retardant properties of expandable polystyrene materials through nanoparticle reinforcement. PhD Thesis, The Graduate School of Natural and Applied Science of Gazi University, Ankara.
📄Lakatos, Á., Csík, A., 2022. Multiscale thermal investigations of graphite doped polystyrene thermal insulation, Polymers, 14(8): 1606.
📄Latif, Z., Ali, M., Lee, E.J., Zubair, Z., Lee, K.H., 2023. Thermal and mechanical properties of nano-carbon-reinforced polymeric nanocomposites: A review. Journal of Composite Science, 7: 441.
📄Levchik, S.V., Weil, E.D., 2008. New developments in flame retardancy of styrene thermoplastics and foams. Polymer International, 57: 431-448.
📄Liu, C., Chen, C., Shen, J., Liu, Y., Xu, D., 2026. Preparation of halogen-free flame retardant expandable polystyrene foam with improved mechanical performance and recyclability. Polymer Degradation and Stability, 247.
📄Lu, H., Wilkie, C.A., 2010. Study on intumescent flame retarded polystyrene composites with improved flame retardancy. Polymer Degradation and Stability, 95(12): 2388-2395.
📄Lyon, R.E., Safronava, N., Crowley, S., Walters, R.N., 2021. A molecular-level fire growth parameter. Polymer Degradation and Stability, 186(2021).
📄Mansour, S., Ibrahim, M.M., 2016. Thermal stability study of polystyrene/graphite microcomposites in comparison with polystyrene/carbon nanocomposites. Arab Journal of Nuclear Science and Applications, 49(4): 79-85.
📄Meuchelböck, J., Raps, D., Brückner, A., Altstadt, V., Ruckdöschel, H., 2024. Flexural fatigue behaviour and damage mechanism of polystyrene bead foams – Influence of the foam density. International Journal of Fatigue, 180.
📄Morgan, A.B., Bundy, M., 2007. Cone calorimeter analysis of UL-94 V-rated plastics. Fire and Materials, 31: 257-283.
📄Musa, A.A., Bello, A., Adams, S.M., Onwualu, A.P., Anye, V.C., Bello, K.A., Obianyo, I.I., 2025. Nano-enhanced polymer composite materials: A review of current advancements and challenges. Polymers, 17: 893.
📄Ramli Sulong, N.H., Syaerah Mustapa, S.A., Abdul Rashid, M.K., 2019. Application of expanded polystyrene (EPS) in buildings and constructions: A review. Applied Polymer Science, 136(20).
📄Reck, L.M., Haberhauer, G., Lüning, U., 2016. Enantiopure chiral concave 1,10-phenanthrolines. European Journal of Organic Chemistry, 46: 2799-2807.
📄Reynoso, L.E., Carrizo Romero, A.B., Viegas, G.M., San Juan, G.A., 2021. Characterization of an alternative thermal insulation material using recycled expanded polystyrene. Construction and Building Materials, 301.
📄Rydzkowski, T., Reszka, K., Szczypiński, M., Szczypiński, M.M., Kopczyńska, E., Thakur, V.K., 2020. Manufacturing and evaluation of mechanical, morphological, and thermal properties of reduced graphene oxide-reinforced expanded polystyrene (EPS) nanocomposites. Advances in Polymer Technology, 2020: ID3053471.
📄Tsai, J.C., Lo, Y.L., Lin, C.Y., Sheu, H.M., Lin, J.C., 2004. Feasibility of rapid quantitation of stratum corneum lipid content by Fourier transform infrared spectrometry. Spectroscopy, 18: 423-431.
📄Tseng, C.H.E., Askeland, D.R., 1992. Thermal and chemical analysis of the foam, refractory coating and sand in the EPS process. AFS Transactions, 100: 509-518.
📄Uhl, F.M., Wilkie, C.A., 2002. Polystyrene/graphite nanocomposites: Effect on thermal stability. Polymer Degradation and Stability, 76(1): 111-122.
📄Wang, A.L., Han, J.L., Tang, Y.P., Lu, M.S., Wang, K., Wu, Z.N., Yin, H.B., 2025. Preparation of antistatic and flame-retardant SDBS-modified graphite nanosheet/polystyrene nanocomposites by in situ suspension polymerization. Journal of Applied Polymer Science, 14(8).
📄Wang, Z., Li, S., Wu, Z., 2015. The fabrication and properties of a graphite nanosheet/polystyrene composite based on graphite nanosheets treated with supercritical water. Composites Science and Technology, 112: 50-57.
📄Yan, Y.W., Chen, L., Jian, R.K., Kong, S., Wang, Y.Z., 2012. Intumescence: An effect way to flame retardance and smoke suppression for polystyrene. Polymer Degradation and Stability, 97(8): 1423-1431.
📄Yeh, S.K., Su, C.C., Huang, J.M., Ke, M.Q., Bogale, D., Anbarasan, R., Tung, K.L., Wang, S.F., 2020. Fabrication of polystyrene/carbon nanocomposites with superior mechanical properties. Polymer Engineering & Science, 60(8): 2046-2056.
📄Yıldırım, A., Acay, H., Baran, F., 2022. Synthesis and characterisation of mushroom-based nanocomposite and its efficiency on dye biosorption via antimicrobial activity. International Journal of Environmental Analytical Chemistry, 102(7): 1545-1562.
📄Yılmaz Doğan, H., Altın, Y., Çelik Bedeloğlu, A., 2021. Investigation of properties of graphene-reinforced epoxy nanocomposites. Journal of Polytechnic, 24(4): 1719-1727.
📄Wang, G., Bai, S., 2017. Synergistic effect of expandable graphite and melamine phosphate on flame-retardant polystyrene. Journal of Applied Polymer Science, 134: 45474.
📄Wang, L., Wang, C., Liu, P., Jing, Z., Ge, X., Jiang, Y., 2018. The flame resistance properties of expandable polystyrene foams coated with a cheap and effective barrier layer. Construction and Building Materials, 176: 403-414.
📄Zhang, C., Li, X., Yang, R., Lan, Y., 2016. Effects of triphenyl phosphate on styrene suspension polymerization process and flame retardance properties of polystyrene/triphenyl phosphate nanocomposite. Colloid and Polymer Science, 294: 1153-1163.
📄Zhang, C., Li, X., Si, C., Yang, R., 2016. Effects of graphite on styrene suspension polymerization and flame retarded expandable polystyrene. Polymeric Materials: Science and Engineering Division, 32(7).
📄Zhao, Z., Cai, W., Xu, Z., Mu, X., Ren, X., Zou, B., Gui, Z., Hu, Y., 2020. Multi-role p-styrene sulfonate assisted electrochemical preparation of functionalized graphene nanosheets for improving fire safety and mechanical property of polystyrene composites. Composites Part B: Engineering, 181: 107544.
📄Zhao, W., Zhao, H.B., Cheng, J.B., Li, W., Zhang, J., Wang, Y.Z., 2022. A green, durable and effective flame-retardant coating for expandable polystyrene foams. Chemical Engineering Journal, 440.