Multi-role p-styrene sulfonate assisted electrochemical preparation of functionalized graphene nanosheets for improving fire safety and mechanical property of polystyrene composites

Polystyrene sulfonate functionalized graphene nanosheets (PSS@GNS) with high quality (I-D/I-G = 0.17) were fabricated through electrochemical exfoliation of bulk graphite followed by simple free radical polymerization in water solution, which is a promising strategy for mass production of polymer functionalized graphene. P-styrene sulfonate anions were used to intercalate into the bulk graphite under voltage and also as monomers of the macromolecule modification agents for the exfoliated graphene nanosheets. Besides, benzene rings and carbon double bonds are considered to be able to capture hydroxyl free radicals which produce defects on graphene sheets during electrochemical exfoliation process, thus improve the quality of the exfoliated graphene nanosheets. Then the graphene nanosheets were incorporated into polystyrene (PS) through a solution blending method to reduce the fire hazards and improve mechanical properties of PS resin. According to the results of cone calorimeter, the introduction of functionalized graphene nanosheets into PS reduces heat release rate (decreased by 40%), total heat release (decreased by 35%) and increases the amount of char residues. The flame retardant improvement is attributed to the barrier effect of well-dispersed graphene nanosheets, limiting the mass transfer of the volatile compounds and forming char layers which blocked polymers from heat and oxygen. Meanwhile, the introduction of PSS@GNS into PS also contributed to increase its strength and elongation rate thanks to the pristine properties of graphene nanosheets and their interfacial interaction with the PS matrix.