Thermal stability of phosphorus-containing styrene–acrylic copolymer and its fire retardant performance in waterborne intumescent coatings

Phosphorus-containing styrene–acrylic copolymers are synthesized by free radical seeded emulsion polymerization with the monomers of MMA/St/BA/MAA and phosphorus-containing vinyl monomer (SIPOMER PAM100). The properties of copolymer films are characterized by water adsorption test, thermogravimetry, Fourier transform infrared spectroscopy (FTIR), and energy dispersive spectroscopy (EDS), etc. The copolymer emulsions are used as the binder in an intumescent coatings formulation, and the fire-retardant performances of the coatings are determined by an instrument which the furnace temperature is analoging the cellulose fire temperature. The water adsorption of copolymer film increases remarkably owing to the increasing of phosphoric acid group in the polymer chain. The thermal decomposition stability and thermal-oxidative decomposition stability of the copolymer are improved when PAM100 is introduced into its chain, which is strongly supported by the FTIR and EDS results of copolymer residual treated at different temperature. The EDS results also illustrate that the fire retardancy enhanced by PAM100 during combustion owing to the condensed-phase mechanism. The fire-retardant test results show that the intumescent coatings using StA-P 1.5 copolymer emulsion as the binder obtains the best fire retardant performance. We suggested that StA-P 1.5 presents the lower reactivity with the acid source (APP) in 275–400 °C, and the higher reactivity with APP when the temperature is greater than 500 °C would be benefit for the swelling–charring process and the final fire retardant performance. The exorbitant crosslinking in StA-P 7 brings a negative effect on the fire-retardant performance of intumescent coatings, even if it introduces a densy swollen char layer.