UV-LED curable acrylic films containing phosphate glass powder: effect of the filler loading on the thermal, optical, mechanical and flame retardant properties

In this work, we thoroughly investigate the effects of the incorporation of a phosphate glass micrometric powder on the morphology, as well as on the thermal, optical, mechanical and flame retardant properties of UV-LED curable acrylic films. To this aim, the filler loading was changed within 10 and 50 wt.%. UV-LED initiated curing was selected as a fast and reliable system, as the standard UV-curing process was not suitable because of the presence of the glass powder that decreased the quantum efficiency during the UV exposure, hence preventing the transformation of the liquid system into a solid network. The glass powder slightly increased the glass transition temperature of the acrylic network, hence showing a limited effect on the chain segments mobility; besides, increasing filler loadings were responsible for a progressive decrease of the transparency of films, irrespective of a marginal effect on their refractive index. Conversely, the presence of increasing amounts of phosphate glass improved the thermal and thermo-oxidative stability of the cured products. Besides, phosphate glass was capable of remarkably enhancing the flame retardance of the acrylic network at 50 wt.% loading, which achieved self-extinction in vertical flame spread tests (and was V-0 rated). This formulation, as assessed by forced-combustion tests, also displayed a remarkable decrease of peak of Heat Release Rate and Total Heat Release (by 44 and 33%, respectively) and of Total Smoke Release and Specific Extinction Area (by 53 and 56%, respectively). Further, the filler promoted an increase of the stiffness and surface hardness of the films, at the expense of a decrease in ductility. All these findings may justify the potential use of these composite films as flame retardant coatings for different flammable substrates.