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Citation: Pellerin, S.; Samyn, F.;
Duquesne, S.; Landry, V. Preparation
and Characterisation of UV-Curable
Flame Retardant Wood Coating
Containing a Phosphorus Acrylate
Monomer. Coatings 2022,12, 1850.
https://doi.org/10.3390/
coatings12121850
Academic Editor: Marko Petric
Received: 12 October 2022
Accepted: 25 November 2022
Published: 29 November 2022
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coatings
Article
Preparation and Characterisation of UV-Curable Flame
Retardant Wood Coating Containing a Phosphorus
Acrylate Monomer
Solène Pellerin 1,2 , Fabienne Samyn 2, Sophie Duquesne 2and Véronic Landry 1, *
1
NSERC–Canlak Industrial Research Chair in Interior Wood-Product Finishes, Department of Wood and Forest
Sciences, UniversitéLaval, Québec City, QC G1V 0A6, Canada
2CNRS, INRAE, Centrale Lille, UMR 8207-UMET-UnitéMatériaux et Transformations, Universitéde Lille,
F-59000 Lille, France
*Correspondence: veronic.landry@sbf.ulaval.ca; Tel.: +1-(418)-656-2131
Abstract:
The application of a flame retardant coating is an effective solution to enhance the fire
retardancy of wood flooring. However, finding the right balance between reducing the flame
propagation and good overall coating properties while conserving wood appearance is complex. In
order to answer this complex problem, transparent ultraviolet (UV)-curable flame retardant wood
coatings were prepared from an acrylate oligomer, an acrylate monomer, and the addition of the
tri(acryloyloxyethyl) phosphate (TAEP), a phosphorus-based monomer, at different concentrations in
the formulation. The coatings’ photopolymerisation, optical transparency, hardness, water sorption
and thermal stability were assessed. The fire behaviour and the adhesion of the coatings applied
on the yellow birch panels were evaluated, respectively, using the cone calorimeter and pull-off
tests. Scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analyses were
performed on the collected burnt residues to obtain a better understanding of the flame retardancy
mechanism. Our study reveals that phosphorus monomer addition improved the coating adhesion
and the fire performance of the coated wood without impacting the photopolymerisation. The
conversion percentage remained close to 70% with the TAEP addition. The pull-off strength reached
1.12 MPa for the coating with the highest P-monomer content, a value significantly different from the
non-flame retarded coating. For the same coating formulation, the peak of heat release rate decreased
by 13% and the mass percentage of the residues increased by 37% compared to the reference. However,
the flame-retarded coatings displayed a higher hygroscopy. The action in the condensed phase of the
phosphorus flame retardant is highlighted in this study.
Keywords: flame retardant; wood coating; phosphorus acrylate; UV-curable coating
1. Introduction
With sustainability questions arising in recent decades, wood is more than ever a ma-
terial of choice for construction. When this renewable resource is supplied from sustainable
forests, wood transformation and use are key in the reduction of the energy embodied in
building materials. Along with the use of biobased materials, wood constructions provide
further energy and greenhouse gas emission savings. In a perspective of limiting global
warming, industries are encouraged to replace high-carbon materials with lower-carbon
alternatives and when possible, with products based on renewable materials [
1
]. Hence,
using wood instead of steel or cement in the construction sector is one example of emission
reduction options. Used since a long time ago for its mechanical properties and visual
aspect, wood can be used for both structural and appearance products such as floors, wall
panels, ceiling tiles and mouldings [
2
]. However, the construction industry has to face one
limitation of wood: its flammability. To promote their use in non-residential buildings,
Coatings 2022,12, 1850. https://doi.org/10.3390/coatings12121850 https://www.mdpi.com/journal/coatings
Coatings 2022,12, 1850 2 of 21
increasing flame retardancy is thus essential. Different strategies can be employed to im-
prove the fire performance of wood, including the impregnation of flame retardants and
the application of flame retardant coatings [
3
]. In the flooring industry, the second option is
usually preferred as it is easier to implement.
Achieving flame retardancy by the application of a flame retardant (FR) coating is
mainly dependent on its formulation and the incorporation of FR components. There
are different types of flame retardants, the main ones being halogenated compounds,
mineral fillers as well as phosphorus- and nitrogen-based compounds. The phosphorus
FR have gained interest in recent decades [
4
]. Phosphorus-based FR may combine a flame
retardancy action in the gaseous phase and in the solid phase [
5
]. Upon phosphorus
FR decomposition, various radicals are released including PO
•
or HPO
2•
[
6
]. These are
able to react by radical recombination with the highly reactive hydrogen H
•
and hydroxy
OH
•
radicals present in the flame. Consequently, oxidation reactions in the flame are
slowed down. The production of heat being reduced, flame propagation is limited. The
action of the phosphorus FR in the solid phase mainly results in its contribution to the
char formation by esterification and dehydration [
6
–
8
]. The generation of acid species
upon temperature elevation leads to further reactions with the surrounding polymer
matrix and its decomposition by-products. The efficacy of the phosphorus FR is strongly
related to its decomposition products’ interaction with the chemical environment in the
pyrolysis zone [9].
High-solid-content ultraviolet (UV)-curable coating is the most common technology
used in the manufacturing of pre-finished flooring. The finishing system is typically
composed of a stain, a tie coat, sealer layers and a topcoat. These coatings are most of the
time acrylate based, as this technology offers an overall good price/property balance. The
curing is performed within seconds and no drying step is required, offering a time gain
compared to waterborne or solvent-borne coatings. The obtained coatings achieve good
hardness and excellent chemical resistance [10–12].
In this context, the development of P-containing UV-curable coatings to improve the
fire performance of wood may represent an interesting approach to widen the use of wood
in the construction industry. Few studies deal with transparent UV-curable coatings offering
a good flame retardancy of coated wood while still preserving its appearance [
13
–
18
].
The addition of FR monomers, reactive diluents, is generally the investigated approach.
Chambhare, Lokhande et al. studied phosphorus- and nitrogen-based monomer addition
in UV-curable wood coating formulations by adding, respectively, the tris-diethanolamine
spirocyclic pentaerythritol bisphosphorate and a difunctional (hydroxypropyl methacrylate)
piperazine modified with cyclic phosphates [
19
,
20
]. They reported an improved fire and
water resistance, higher crosslinking density, but a loss of adhesion on wood. However,
the flame retardancy has only been assessed on the coating and not on the coating/wood
assembly. Naik et al. also reported the preparation of FR wood coating based on phosphorus
and silicon monomers [
21
]. The coating showing a good adhesion and hardness as well
as the best UL-94 rating was a blend with both monomers. The authors attributed the
enhancement in flame retardancy to the synergistic effect of phosphorous and silicon. A
similar study was conducted with a P,N-containing monomer [
22
]. In both studies, the
intrinsic flame retardant properties of the coatings were assessed by the UL-94 test and
the limiting oxygen index (LOI) assessment. The synergy of three monomers containing,
respectively, P, S and N elements, the triallyl orthophosphate, the pentaerythritol tetrakis
(3-mercaptopropionate), and, the N-dimethylacrylamide, was also investigated in another
publication [
14
]. UV-curable coating formulations were applied on Chinese fir wood
samples and UL-94 tests were performed. After fire exposure, the authors reported the
formation of an intumescent char layer for some coatings thanks to the release of NH
3
and
CO
2
, non-flammable gases during the degradation process. In those studies, the mechanical
properties of the coatings were not always thoroughly studied. Furthermore, it appears
that the flame retardancy characteristic of the coatings is not systematically assessed in the
final condition of use, particularly on the wood/coating assembly.
Coatings 2022,12, 1850 3 of 21
By enlarging the literature review of acrylic-based FR coatings to non-wood applica-
tions, a monomer seems particularly interesting, namely the tri(acryloyloxyethyl) phos-
phate (TAEP). The fire retardancy of the monomer has already been highlighted in several
studies [
23
–
25
]. The synthesis of the trifunctional phosphate acrylate monomer was firstly
reported by Liang and Shi [
26
]. They further studied the thermal degradation of different
blends of the TAEP monomer with an epoxy acrylate oligomer or with a polyurethane
one [
23
]. The LOI improved with an increased TAEP content. The highest loading allowed
to reach a V0 rating at the UL-94 test for both oligomer mixes. With the thermal degradation
of the TAEP phosphate groups, polyphosphoric acids were formed, contributing to the char
development. The authors highlighted a particularly effective degradation catalysation
action on the epoxy acrylate oligomer. The TAEP addition to an epoxy acrylate oligomer
led to a viscosity decrease while promoting the photopolymerisation rates and the thermal
stability of the UV-cured resins [
24
]. The authors reported a V0 rating during the UL-94 test
with a TAEP content of 50% in the formulation. TAEP was also used to prepare a silicon-
containing hyperbranched polyphosphonate acrylate (HPA), which was then blended with
an epoxy acrylate oligomer [
25
]. In this study, Wang et al. also highlighted the effectiveness
of the phosphorus derivative to catalyse the degradation of the oligomer, helping in the
formation of a char layer. The transparent HPA-based coatings displayed an improved LOI
value and a decreased pHRR and THR. However, the coatings failed to reach a V0 rating
for the UL-94 classification with the FR addition. TAEP was also used to develop a FR
coating for polyester fabrics [27]. The textiles were plasma-treated before being dipped in
the FR formulations and then exposed to UV light. The authors reported an excellent flame
retardant property obtained from dipping the fabrics in a blend of TAEP with another FR
compound, a 9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide (DOPO) derivative.
The improved washing resistance was attributed to the surface plasma treatment.
Using flame-retarded UV-curable finishing layers could be a strategy to achieve the
flame retardant performances of flooring. However, there is no solution thoroughly de-
scribed in the literature that enables to fulfil all the specifications targeted. The aim of this
present work is thus to evaluate the use of TAEP in a high-solid-content UV-curable wood
sealer coat formulations not only with regard to the fire properties but also the other key
performances expected from a coating. High-solid-content UV-curable coatings were thus
prepared with different phosphorus monomer percentages. Two layers were applied on
wood samples, with a low thickness of 25
µ
m per coat. The photopolymerisation kinetics
were monitored by photo-differential scanning calorimetry (photo-DSC). The coating opti-
cal transparency was measured as a wood flooring coating is usually expected to preserve
or improve wood appearance. Other coating properties such as hardness, water sorption
and thermal stability were also studied. The wood coating adhesion was evaluated by pull-
off tests. This study also highlights the flame retardance behaviour of the wood/coating
assembly, studied by cone calorimetry. Scanning electron microscopy (SEM) and energy-
dispersive spectroscopy (EDS) analyses were performed on the collected residues after the
cone calorimetry test to complete the characterisation of the FR coating property.
2. Experimental Section
2.1. Materials
The coatings were prepared with different phosphorus monomer concentrations.
Formulations are presented in Table 1. They are based on typical formulations used as
sealers for prefinished wood flooring. Both the difunctional epoxy acrylate oligomer
(referred as oligomer) and the acrylate monomer tripropylene glycol diacrylate (TPGDA)
were supplied by Arkema (Burlington, ON, Canada). The photoinitiator, 2-hydroxy-2-
methylpropiophenone (Sigma-Aldrich, Oakville, ON, Canada), was added at 3 wt%. A
polybutadiene additive (Cray Valley, Stratford, CT, USA) was used for its defoaming
properties at 0.01 wt% in the formulation. All products were graciously provided by Canlak
(Daveluyville, QC, Canada).
Coatings 2022,12, 1850 4 of 21
Table 1. Composition of the UV-curable wood coating formulations.
Raw Material F0 F1 F2
Oligomer 47.0 47.0 47.0
TPGDA 50.0 30.9 11.7
TAEP 0.0 19.1 38.3
Ricon 130 0.01 0.01 0.01
Photoinitiator 3.0 3.0 3.0
The phosphorus monomer, TAEP, was prepared by the addition of phosphorus oxy-
chloride to hydroxylethyl acrylate (Sigma-Aldrich, Oakville, ON, Canada) following the
synthesis described by Liang and Shi [
26
]. All the products were used as received without
further purification. Proton nuclear magnetic resonance (
1
H NMR) and Fourier-transform
infrared spectroscopy (FTIR) analyses, respectively, displayed in Figures S1 and S2 in the
supplementary information, showed the expected structure of TAEP. Its phosphorus con-
centration was also confirmed by inductively coupled plasma optical emission spectrometry
(ICP-OES) analysis.
Yellow birch (Betula alleghaniensis Britt.) 4.5 mm thick lamellas were provided by
Mirage (Saint-Georges, Canada). Raw sawn planks were placed in a conditioning room
until mass equilibrium. Relative humidity was set at 42% and temperature at 23
◦
C,
allowing wood samples to reach a moisture content of approximately 8%. Wood samples
free from knots and defects were used in this study.
2.2. Sample Preparation
Depending on the analysis performed, coatings were either applied on wood samples,
steel plates (Type R Q-panels, Q-LAB, Westlake, OH, USA) or on glass panels cleaned
with ethanol.
Sample preparation occurred in different stages as shown on Figure 1, with the ex-
ample of the steps followed prior to the cone calorimeter test. Before coating applications,
the wood sample surface was prepared using a 3-step gradual sanding. A first pass was
performed at a P-120-grit, then P-150 and the sanding was finalised at P-180. To do so,
an automatic sander 36 CCK 1150 (Costa levigatrici S.p.A., Schio, Italy) equipped with
paper sanding belts (aluminium oxide type, Abrasifs JJS Inc., Newmarket, ON, Canada)
was used.
Prepared formulations were homogenised using a spatula and placed in an ultrasonic
bath during 15 min for degassing before use. Formulation viscosity was measured with
a piston-type viscometer (ViscoLab 4100, Cambridge Applied Systems Inc., Boston, MA,
USA) at 23
◦
C. Coatings were applied on wood samples, glass or steel plates with a 25
µ
m
wire-wound rod (BYK Gardner, Columbia, SC, USA). To be closer to what is performed
in the industry, it was applied in two layers, each of 25
µ
m. Before applying the second
layer, the coating surface was lightly sanded with a P-400-grit paper to promote interlayer
adhesion. A 4-sided applicator (BYK Gardner, Columbia, SC, USA) was used for the
application when a higher film thickness was necessary for characterisation tests. When the
free films were required, coatings were applied on glass panels, cured, and then carefully
pealed of the substrate with a razor blade.
Curing was performed under a medium-pressure mercury vapour lamp on a con-
veyor at a 5 m
·
min
−1
speed under atmospheric conditions. Lamp intensity was set at
500 mW
·
cm
−2
, corresponding to an energy dose of 430–450 mJ
·
cm
−2
in the UVA range.
The intensity and energy doses were measured before and after curing with a Power Puck
II radiometer (EIT, Leesburg, VA, USA).
Coatings 2022,12, 1850 5 of 21
Coatings 2022, 12, x FOR PEER REVIEW 5 of 24
Figure 1. Wood sample preparation for the cone calorimeter test.
Prepared formulations were homogenised using a spatula and placed in an ultra-
sonic bath during 15 min for degassing before use. Formulation viscosity was measured
with a piston-type viscometer (ViscoLab 4100, Cambridge Applied Systems Inc., Boston,
MA, USA) at 23 °C. Coatings were applied on wood samples, glass or steel plates with a
25 µ m wire-wound rod (BYK Gardner, Columbia, SC, USA). To be closer to what is per-
formed in the industry, it was applied in two layers, each of 25 µ m. Before applying the
second layer, the coating surface was lightly sanded with a P-400-grit paper to promote
interlayer adhesion. A 4-sided applicator (BYK Gardner, Columbia, SC, USA) was used
for the application when a higher film thickness was necessary for characterisation tests.
When the free films were required, coatings were applied on glass panels, cured, and then
carefully pealed of the substrate with a razor blade.
Curing was performed under a medium-pressure mercury vapour lamp on a con-
veyor at a 5 m·min−1 speed under atmospheric conditions. Lamp intensity was set at 500
mW·cm−2, corresponding to an energy dose of 430–450 mJ·cm−2 in the UVA range. The
intensity and energy doses were measured before and after curing with a Power Puck II
radiometer (EIT, Leesburg, VA, USA).
2.3. Study of the Coating Photopolymerisation
The impact of trifunctional phosphorus monomer addition on the curing behaviour
was monitored by photo-DSC. A DSC822e differential scanning calorimeter (Mettler To-
ledo, Columbia, USA) coupled with a Lightningcure LC5 mercury-xenon lamp (Hama-
matsu Photonics K.K., Iwata, Japan) was used in order to measure the enthalpies of reac-
tion during photopolymerisation. To ensure repeatability, lamp intensity was verified
with a radiometer (C6080-02, Hamamatsu Photonics K.K., Iwata, Japan). Experiments
Sanding (P-180) and cutting samples
114 mm
1219 mm
100 mm
100 mm
Coating application (25 μm)
Curing (500 mW.cm−2) and sanding (P-400)
Second coating application (25 μm)
Second curing (500 mW.cm
−2
)
Figure 1. Wood sample preparation for the cone calorimeter test.
2.3. Study of the Coating Photopolymerisation
The impact of trifunctional phosphorus monomer addition on the curing behaviour
was monitored by photo-DSC. A DSC822e differential scanning calorimeter (Mettler Toledo,
Columbia, USA) coupled with a Lightningcure LC5 mercury-xenon lamp (Hamamatsu
Photonics K.K., Iwata, Japan) was used in order to measure the enthalpies of reaction
during photopolymerisation. To ensure repeatability, lamp intensity was verified with
a radiometer (C6080-02, Hamamatsu Photonics K.K., Iwata, Japan). Experiments were
performed under air atmosphere at 30
◦
C. A coating drop of 2.5
±
0.1 mg was centred
in an open aluminium pan. The sample was then irradiated for 60 s at 50 mW
·
cm
−2
.
Each formulation was tested four times. All DSC exotherms were normalised to sample
weight. The photopolymerisation exotherms resulting from photo-DSC allow the calcula-
tion of Rp, the rate of polymerisation, the unsaturation conversion and t
ind
, the induction
time. The induction time corresponds to the necessary time to achieve 1% of conversion.
The polymerisation rate Rp and the conversion percentage were calculated according to
Equations (1) and (2)
, respectively. Both depend on
∆Htheo
, the theoretical heat flow for the
complete conversion of the acrylate system expressed in J
·
g
−1
. For calculations, a value
of 86 kJ
·
mol
−1
was taken for the heat of the polymerisation per acrylic unsaturation [
28
].
dH/dt
corresponds to the measured heat flow at time tand
∆Ht
to the heat flow generated
up to time t.
Rp =(dH/dt)
∆Htheo
(1)
%Conversion =∆Ht
∆Htheo ×100 (2)
2.4. Characterisation of the Coating
The coating optical transparency was evaluated by transmittance on a Cary 60 ultraviolet–
visible (UV–Vis) spectrophotometer (Agilent Technologies, Santa Clara, CA, USA). Analyses
were carried out on 100
µ
m thick free films with a scanning wavelength ranging from
400 to 800 nm and using a medium scanning speed (600 nm
·
min
−1
). An approximation
of the glass transition temperature (T
g
) and the crosslinking density of the cured films
Coatings 2022,12, 1850 6 of 21
were calculated from dynamic mechanical analysis (DMA) measurements, performed on a
DMA Q800 supplied by TA Instruments (New Castle, USA). DMA apparatus was operated
in a tensile mode with the frequency set at 1 Hz and the amplitude at 10
µ
m. A force
track of 125% was applied. Measurements were performed at a constant heating rate of
3
◦
C
·
min
−1
in a temperature range from 30
◦
C to 150
◦
C. Coating-free films were laser
cut in a rectangular shape of 25 mm per 5 mm, with a thickness of approximately 100
µ
m.
Prior to the test, films were dried at 100
◦
C during 24 h to avoid any influence of entrapped
water. Five repetitions were run per coating formulation. The storage modulus (E
0
) and loss
modulus (E”) resulting from the dynamic mechanical analysis allow the calculation of the
loss factor (tan
δ
), defined as the ratio of E” over E
0
. The storage modulus (E
0
) represents
the elastic portion, while the loss modulus (E”) characterises the viscous behaviour of the
material. In this study, the maximum of the loss factor was used to approximate the glass
transition temperature. The crosslinking density was calculated according to Equation (3).
E
0
min
corresponds to the minimum of storage modulus expressed in Pa, Tis the temperature
at the minimum of storage modulus and Rrefers to the ideal gas constant.
νLD =E0
min
3RT (3)
Pendulum hardness tests were performed according to the standardised test method
ASTM D4366-16 using a König pendulum tester (BYK Gardner, Columbia, USA). The pen-
dulum was placed on the coating applied on a glass plate and set at a 6
◦
angle to the coating
surface normal. The number of oscillations were recorded during pendulum damping
from a 6
◦
to 3
◦
angle. Five replicas per formulations were tested for the calculations of the
mean values and standard deviations. Dynamic instrumented indentations were carried
out on a Micro-Combi tester (CSM Instruments, Peseux, Switzerland) with a diamond
Berkovich indenter calibrated on fumed silica beforehand. The indenter tip was led normal
to a coating surface applying a maximum load of 300 mN. The force was gradually applied
in 5 s, held during 2 s before being unloaded on a 3 s period. Indentation tests were
performed 5 times for each sample, on at least 3 repetitions per formulation. For this test,
coatings were applied on steel panels with a thickness of 125
µ
m. Higher thickness than the
attended application is mandatory in order to have an adequate indenter penetration depth.
Steel panels were preferred over wood to ensure substrate hardness homogeneity. Water
content was determined with an 890 Titrando titrator for volumetric Karl Fischer titrations
equipped with the software Tiamo
TM
Light (Metrohm AG, Herisau, Switzerland). Coating
flakes with a thickness of 100
µ
m were dispersed in N,N-dimethylformamide and then
placed in an ultrasonic bath for an hour prior to the Karl Fischer titrations. The analyses
were performed twice per formulation. To assess the potential influence of adding phospho-
rus derivatives on the water uptake of the coating films, sorption and desorption isotherms
were performed in triplicate on 10 mg film samples with a thickness of 100
µ
m. Before the
experiments, the samples were dried overnight in an oven at 100
◦
C. Tests were performed
on a DVS Adventure water vapour sorption analyser (Surface Measurement Systems, Al-
lentown, USA) at a constant temperature of 25
◦
C. First, a step at 0% relative humidity (RH)
was performed to allow mass stabilisation. Then, RH was increased from 0% to 95% by
means of 5% steps and scaled back down using the same increment. The relative humidity
of the analysis chamber was maintained until the sample mass percentage varies less than
0.0001% over a 5 min period or the step time exceeds 24 h. Thermogravimetric analyses
(TGAs) were performed on a TGA 851e analyser (Mettler Toledo, Greifense, Switzerland).
Experiments were carried out under a nitrogen flow (50 mL
·
min
−1
) from
25 ◦C
to 800
◦
C at
a heating rate of 10
◦
C
·
min
−1
. To avoid any interaction with the phosphorus derivatives, a
sapphire crucible (70
µ
L) was used. All experiments were performed in triplicate on free
50 µm
thick coating films. Characteristic data such as T
5%
, the temperature corresponding
to 5% of degradation, T
max
, the temperatures of the maximum degradation rates and the
percentages of residues at 800 ◦C were determined.
Coatings 2022,12, 1850 7 of 21
2.5. Characterisation of the Coating Adhesion on Wood
Adhesion was investigated using pull-off tests based on the test method described in
the ASTM D4541-17 standard. Aluminium dollies with a diameter of 20 mm were glued
on the coating using a two-component epoxy adhesive (Lepage Marine Epoxy, Henkel,
Mississauga, ON, Canada). Prior to the glue application, the dolly surface was sanded
with a P-150-grit paper and cleaned with a wipe. The same procedure was performed on
the coating surface with a finer sanding paper (P-1500-grit). Steel hex nuts (79 g) were
placed on dollies during the adhesive curing to ensure an even pressure applied on each
sample. After 48 h, the test area around the dolly was scored by means of a dolly cutter,
until the wood substrate was reached. This ensures testing the same surface area. Pull-off
tests were carried out on a QTest/5 Elite electromechanical test system with a 5 kN load cell
(MTS, Eden Prairie, MN, USA) at a 2 mm
·
min
−1
pull rate. The coating tensile strength was
calculated according to Equation (4), where F
max
corresponds to the load at fracture (N) and
d, to the dolly diameter (mm). Fracture type was visually assessed based on the described
method in the ISO 4624:2016 standard. Twenty repetitions per formulation were performed.
σ=4Fmax
πd2(4)
The statistical analysis of data was achieved on the software R: a language and envi-
ronment for statistical (R Foundation for Statistical Computing, Vienna, Austria). Prior to
analysis, the normal distribution of residuals was examined as well as the homogeneity
of variances to ensure the validity of the analysis. One-way ANOVA was executed to
compare the impact of phosphorus monomer addition in the coating formulations on the
pull-off strength. The Tukey’s HSD test allowed a pairwise comparison between the group
to identify significant differences at a 0.05 level.
2.6. Fire Performance of Coated Wood Samples
The fire behaviour of the treated wood samples was assessed on a dual cone calorime-
ter (Fire Testing Technology, East Grinstead, UK). Cone calorimeter is a bench-scale test
method widely used to assess a material’s fire behaviour. It gives different parameters as the
heat release rate, the time to ignition or the mass loss of the combusting material. However,
it offers a limited interpretation of a fire scenario as it does not consider flame spreading.
Experiments were carried out on 100
×
100 mm samples placed in the horizontal
position. The distance between the sample and the cone heater was set at 25 mm. Heat
flux was set at 35 kW
·
m
−2
for the cone calorimeter tests, corresponding to an early de-
veloping fire scenario. Such a heat flux is recommended for explanatory testing [
29
]. It
is particularly appropriate to assess flame-retarded polymers as it matches the fire stage
in which their action is crucial. Ignition was forced and the test was stopped 120 s after
flame extinction. Wood sample backsides were wrapped in aluminium foil before being
put in the sample holder. All experiments were performed in quadruplicate. In order to
characterise the fire behaviour of the sample, the following data were gathered: the average
time to ignition (TTI), the average peak of the heat release rate (pHRR) and the average
total heat released (THR).
Cone calorimeter residues were collected and characterised with an Inspect F50 SEM
equipped with a field emission gun source (FEI, Hillsboro, OR, USA). Elemental analysis on
the residues was performed by means of energy dispersive spectroscopy (Octane Super-A,
EDAX-AMETEK, Mahwah, NJ, USA). The acceleration voltage was set at 15 kV. Prior to
analysis, all samples were covered with a conductive Au/Pd deposit.
3. Results
3.1. Photopolymerisation
DSC analysis assesses the heat flow of a material as a function of time and temperature
compared to a reference. When coupled with a UV lamp, it enables the measurement of
Coatings 2022,12, 1850 8 of 21
different parameters specific to photo-curable systems. Photo-DSC results are presented in
Figure 2and Table 2.
Coatings 2022, 12, x FOR PEER REVIEW 8 of 24
The fire behaviour of the treated wood samples was assessed on a dual cone calorim-
eter (Fire Testing Technology, East Grinstead, UK). Cone calorimeter is a bench-scale test
method widely used to assess a material’s fire behaviour. It gives different parameters as
the heat release rate, the time to ignition or the mass loss of the combusting material.
However, it offers a limited interpretation of a fire scenario as it does not consider flame
spreading.
Experiments were carried out on 100 × 100 mm samples placed in the horizontal po-
sition. The distance between the sample and the cone heater was set at 25 mm. Heat flux
was set at 35 kW·m −2 for the cone calorimeter tests, corresponding to an early developing
fire scenario. Such a heat flux is recommended for explanatory testing [29]. It is particu-
larly appropriate to assess flame-retarded polymers as it matches the fire stage in which
their action is crucial. Ignition was forced and the test was stopped 120 s after flame ex-
tinction. Wood sample backsides were wrapped in aluminium foil before being put in the
sample holder. All experiments were performed in quadruplicate. In order to characterise
the fire behaviour of the sample, the following data were gathered: the average time to
ignition (TTI), the average peak of the heat release rate (pHRR) and the average total heat
released (THR).
Cone calorimeter residues were collected and characterised with an Inspect F50 SEM
equipped with a field emission gun source (FEI, Hillsboro, OR, USA). Elemental analysis
on the residues was performed by means of energy dispersive spectroscopy (Octane Su-
per-A, EDAX-AMETEK, Mahwah, NJ, USA). The acceleration voltage was set at 15 kV.
Prior to analysis, all samples were covered with a conductive Au/Pd deposit.
3. Results
3.1. Photopolymerisation
DSC analysis assesses the heat flow of a material as a function of time and tempera-
ture compared to a reference. When coupled with a UV lamp, it enables the measurement
of different parameters specific to photo-curable systems. Photo-DSC results are pre-
sented in Figure 2 and Table 2.
Figure 2. Polymerisation rate of the different coatings.
Table 2. Coating viscosity and photo-DSC results including the induction time, the maximum heat
flow, the rate of polymerisation and the unsaturation conversion.
Formulation
Viscosity
(cP, 23 °C)
tind
(s)
Hmax
(W.g−1)
Rpmax
(s−1)
%Conversion
(%)
Figure 2. Polymerisation rate of the different coatings.
Table 2.
Coating viscosity and photo-DSC results including the induction time, the maximum heat
flow, the rate of polymerisation and the unsaturation conversion.
Formulation Viscosity
(cP, 23 ◦C)
tind
(s)
Hmax
(W.g−1)
Rpmax
(s−1)
%Conversion
(%)
F0 630 1.06 ±0.04 58 ±2 16.1 ±0.4 68 ±3
F1 840 1.10 ±0.02 60 ±1 16.1 ±0.4 69 ±1
F2 1230 1.13 ±0.01 60 ±3 15.3 ±0.7 67 ±2
All the rates of polymerisation curves demonstrated a steep increase within a few
seconds after the beginning of the irradiation. Then, a rapid decrease in the rate of poly-
merisation was observed. Such a heat flow or a Rp behaviour was already reported in
the literature for the free radical polymerisation of acrylate systems [
30
,
31
]. The rate of
polymerisation of free radical polymerisation can be divided into different steps. The
induction period is followed by the autoacceleration step, also called the Trommsdorff gel
effect or the Norrish
−
Smith effect. Rp drastically increases due to the increasing viscosity of
the polymerising system that slows termination reactions [
32
]. After reaching its maximum,
Rp diminishes during the phase of autodeceleration. The propagation is then controlled
through diffusion [
33
]. In this study, Rp
max
were in the same range, with a value of 15.3 s
−1
for F2 and 16.1 s
−1
for the other systems. The conversion percentages were close to 70% for
all coating formulations. The conversion percentages being kept in the same range when
replacing the TPGDA by the phosphorus monomer demonstrated its active participation in
the curing reaction. Thus, TAEP was successfully incorporated in the polymeric network
created during the photopolymerisation of F1 and F2 coatings. No major difference in the
induction time nor in the maximum heat flow, Hmax , was noticed.
In the literature, a sharp peak in the rate of photopolymerisation was also observed
for TAEP containing formulations [
34
,
35
]. However, Rp
max
varied with the phosphorus
monomer content. Tests were performed at 2.4 mW.cm
−2
or at a lower irradiance, greatly
inferior to the 50 mW.cm
−2
used in this study. Such an irradiance was chosen so as to be
more realistic to assess the photopolymerisation behaviour for an industrial application.
Lower irradiance generates less energy, and hence, the polymerisation rate is slower.
Moreover, the gelation effect induced by the trifunctional monomer addition in the system
is greater, explaining the difference in the Rp
max
value. The literature also reports that
Coatings 2022,12, 1850 9 of 21
Rp tends to increase when the formulation viscosity decreases [
36
]. The viscosity is an
important parameter for UV-curable systems as it affects different properties such as the
ease of application, levelling, polymerisation rate and adhesion. In the present study, the
viscosity varied significantly between the formulations (Table 2). However, the addition of
TAEP, a non-linear phosphorus monomer, even at a high percentage in the formulation,
did not affect the UV-curing behaviour.
3.2. Coating Properties
3.2.1. Optical Transparency
Achieving transparency is an important parameter for wood coatings as they are often
designed to protect the substrates while keeping their natural aspect. Film transparency
was assessed by spectrophotometry on the visible spectrum, between 400 and 800 nm
(Figure 3). F0 film was transparent with an 88% transmittance at 600 nm. With the addition
of the FR monomer, the F1 and the F2 coatings also exhibited good optical transparency
with a transmittance higher than 87% at 600 nm. All coatings preserved wood aspect as
shown on Figure S3 in the supplementary information.
Coatings 2022, 12, x FOR PEER REVIEW 11 of 24
Figure 3. UV–Vis transmittance spectra of the coating film.
3.2.2. Coating Mechanical Properties
All the factors impacting the chain mobility, such as the steric hindrance, the polymer
functionality, the nature of the moving segment or the free volume available for motion,
will affect the glass transition temperature. Both monomers added in the formulations in
this study, TPGDA and TAEP, differ in their backbone structures and their number of
acrylate functionalities. Such differences in chemical composition may lead to polymers
exhibiting different Tg and crosslinking densities [37].
DMA results are displayed in Figure 4; the storage modulus (E′) and the tan δ curves
are shown in Figure S4 of the supplementary information. The glass transition tempera-
ture increased along with TAEP loading. Tg reached 75 °C for F2, ten degrees higher than
the one of F0. The oligomer supplier indicates a Tg at 51 °C, measured by DSC. The Tg of
the TAEP homopolymer is also known (105 °C) as it has already been measured and re-
ported in the literature [34,35]. While the value of Tg increased with the phosphorus mon-
omer percentage in the formulation, the crosslinking densities were in the same range.
Given the standard deviation, the crosslinking densities were not considered to be differ-
ent. The width of the tan δ curves remained constant, evidencing good miscibility between
the phosphate monomer and the acrylate monomer, TPGDA, and the epoxy acrylate oli-
gomer.
Figure 3. UV–Vis transmittance spectra of the coating film.
3.2.2. Coating Mechanical Properties
All the factors impacting the chain mobility, such as the steric hindrance, the polymer
functionality, the nature of the moving segment or the free volume available for motion,
will affect the glass transition temperature. Both monomers added in the formulations
in this study, TPGDA and TAEP, differ in their backbone structures and their number of
acrylate functionalities. Such differences in chemical composition may lead to polymers
exhibiting different Tgand crosslinking densities [37].
DMA results are displayed in Figure 4; the storage modulus (E
0
) and the tan
δ
curves
are shown in Figure S4 of the supplementary information. The glass transition temperature
increased along with TAEP loading. T
g
reached 75
◦
C for F2, ten degrees higher than the
one of F0. The oligomer supplier indicates a T
g
at 51
◦
C, measured by DSC. The T
g
of the
TAEP homopolymer is also known (105
◦
C) as it has already been measured and reported
in the literature [
34
,
35
]. While the value of T
g
increased with the phosphorus monomer
percentage in the formulation, the crosslinking densities were in the same range. Given
the standard deviation, the crosslinking densities were not considered to be different. The
width of the tan
δ
curves remained constant, evidencing good miscibility between the
phosphate monomer and the acrylate monomer, TPGDA, and the epoxy acrylate oligomer.
Coatings 2022,12, 1850 10 of 21
Coatings 2022, 12, x FOR PEER REVIEW 12 of 24
Figure 4. Crosslinking density and glass transition temperature of the coatings.
Hardness refers to an imprecise term since its definition varies in the literature [38].
A broad definition of the surface hardness corresponds to the coating resistance to defor-
mation by means of the indentation or the penetration of a solid object [39,40]. This is the
reason why two technics (pendulum and indentation) were used in this study to deter-
mine the hardness of the coatings. The results are reported in Figure 5.
Figure 5. Pendulum hardness and indentation results of the coating films.
The pendulum hardness results exhibited a higher damping property for the coatings
containing the phosphorus monomer. The F0 film reached 108 oscillations, while F1 and
F2 achieved 89 and 78 oscillations, respectively. Replacing TPGDA by the TAEP monomer
led to a change in the viscoelastic properties of the coating. The phosphorus-containing
films were able to dissipate the pendulum energy of motion more easily.
Indentation hardness quantifies the coating film ability to resist to the penetration of
an indenter. Preliminary tests confirmed that the maximum applied load ensured that the
Figure 4. Crosslinking density and glass transition temperature of the coatings.
Hardness refers to an imprecise term since its definition varies in the literature [
38
].
A broad definition of the surface hardness corresponds to the coating resistance to defor-
mation by means of the indentation or the penetration of a solid object [
39
,
40
]. This is the
reason why two technics (pendulum and indentation) were used in this study to determine
the hardness of the coatings. The results are reported in Figure 5.
Coatings 2022, 12, x FOR PEER REVIEW 12 of 24
Figure 4. Crosslinking density and glass transition temperature of the coatings.
Hardness refers to an imprecise term since its definition varies in the literature [38].
A broad definition of the surface hardness corresponds to the coating resistance to defor-
mation by means of the indentation or the penetration of a solid object [39,40]. This is the
reason why two technics (pendulum and indentation) were used in this study to deter-
mine the hardness of the coatings. The results are reported in Figure 5.
Figure 5. Pendulum hardness and indentation results of the coating films.
The pendulum hardness results exhibited a higher damping property for the coatings
containing the phosphorus monomer. The F0 film reached 108 oscillations, while F1 and
F2 achieved 89 and 78 oscillations, respectively. Replacing TPGDA by the TAEP monomer
led to a change in the viscoelastic properties of the coating. The phosphorus-containing
films were able to dissipate the pendulum energy of motion more easily.
Indentation hardness quantifies the coating film ability to resist to the penetration of
an indenter. Preliminary tests confirmed that the maximum applied load ensured that the
Figure 5. Pendulum hardness and indentation results of the coating films.
The pendulum hardness results exhibited a higher damping property for the coatings
containing the phosphorus monomer. The F0 film reached 108 oscillations, while F1 and F2
achieved 89 and 78 oscillations, respectively. Replacing TPGDA by the TAEP monomer led
to a change in the viscoelastic properties of the coating. The phosphorus-containing films
were able to dissipate the pendulum energy of motion more easily.
Indentation hardness quantifies the coating film ability to resist to the penetration
of an indenter. Preliminary tests confirmed that the maximum applied load ensured
that the penetration was restricted to the upper part of the coating film. Having an
Coatings 2022,12, 1850 11 of 21
optimal penetration depth guarantees a minimised influence of the substrate mechanical
property on the results. The coating film containing only the acrylate monomer attained
an instrumented hardness of approximately 65 MPa. With the addition of phosphorus
monomer, the capacity to withstand penetration distinctly dropped under 45 MPa for both
F1 and F2 formulations. The reduced elastic modulus E
r
also followed the same trend,
decreasing with a higher phosphorus content. Even though the conversion rate as well
as the crosslinking density were not affected by the phosphorus monomer addition, a
change in mechanical properties was observed. While TAEP had a higher functionality,
the presence of the P-monomer brought flexibility to the coating films. The presence of
water in the P-containing films was evidenced by further tests. The plasticising effect of the
trapped water in the coating film is one possible explanation for their increased flexibility.
3.2.3. Coating Water Sorption
Using phosphorus-containing polymers in a coating may cause some concern. Phos-
phorus polymers could be sensitive to moisture and in particular, P-O-C linkages present
hydrolytic instability [
41
]. In order to assess the coating water affinity, Karl Fischer titration
and dynamic vapour sorption experiments (DVS) measurements (Figure 6) were performed.
Coatings 2022, 12, x FOR PEER REVIEW 13 of 24
penetration was restricted to the upper part of the coating film. Having an optimal pene-
tration depth guarantees a minimised influence of the substrate mechanical property on
the results. The coating film containing only the acrylate monomer attained an instru-
mented hardness of approximately 65 MPa. With the addition of phosphorus monomer,
the capacity to withstand penetration distinctly dropped under 45 MPa for both F1 and
F2 formulations. The reduced elastic modulus Er also followed the same trend, decreasing
with a higher phosphorus content. Even though the conversion rate as well as the cross-
linking density were not affected by the phosphorus monomer addition, a change in me-
chanical properties was observed. While TAEP had a higher functionality, the presence of
the P-monomer brought flexibility to the coating films. The presence of water in the P-
containing films was evidenced by further tests. The plasticising effect of the trapped wa-
ter in the coating film is one possible explanation for their increased flexibility.
3.2.3. Coating Water Sorption
Using phosphorus-containing polymers in a coating may cause some concern. Phos-
phorus polymers could be sensitive to moisture and in particular, P-O-C linkages present
hydrolytic instability [41]. In order to assess the coating water affinity, Karl Fischer titra-
tion and dynamic vapour sorption experiments (DVS) measurements (Figure 6) were per-
formed.
Figure 6. Karl Fischer titration results and, sorption and desorption curves of the coating films. The
hollow circles correspond to the sorption step while the filled circles correspond to the desorption
one.
Karl Fischer titration quantifies both free and bound water present in the coating film.
The coating without P-monomer contained 0.82% of residual water. The water content
rose with the phosphorus addition to achieve 1.30% for F2 coating. These results were
consistent with the early stage TGA measurements (Figure 7) showing a higher mass de-
crease for the phosphorus-containing films. This gap in mass loss could be explained by
their higher water content released below 150 °C.
DVS measures the quantity of water absorbed by the coating film in a given range of
vapour concentrations. For the F0 film, water absorption was limited, and the mass gain
reached 1.90% at the highest RH. The F2 sorption isotherm showed a steep increase in
high-relative-humidity percentages. Such behaviour, corresponding to a low intake at low
pressures followed by an increased in the high pressures, is typical of a Type III isotherm
Figure 6.
Karl Fischer titration results and, sorption and desorption curves of the coating films. The
hollow circles correspond to the sorption step while the filled circles correspond to the desorption one.
Karl Fischer titration quantifies both free and bound water present in the coating film.
The coating without P-monomer contained 0.82% of residual water. The water content rose
with the phosphorus addition to achieve 1.30% for F2 coating. These results were consistent
with the early stage TGA measurements (Figure 7) showing a higher mass decrease for
the phosphorus-containing films. This gap in mass loss could be explained by their higher
water content released below 150 ◦C.
DVS measures the quantity of water absorbed by the coating film in a given range
of vapour concentrations. For the F0 film, water absorption was limited, and the mass
gain reached 1.90% at the highest RH. The F2 sorption isotherm showed a steep increase in
high-relative-humidity percentages. Such behaviour, corresponding to a low intake at low
pressures followed by an increased in the high pressures, is typical of a Type III isotherm
defined in the International Union of Pure and Applied Chemistry nomenclature [
42
].
F1 displayed a similar water uptake profile to a minor extent, as the mass change at the
maximum RH reached 5.98% instead of 15.3% for F2. The F2 desorption isotherm did
not return to a null mass change at a 0% RH. The hypothesis was made that the water is
still present in the sample. Further energy seemed to be necessary to remove the bound
water. This latter was removed prior to the DVS test by heating during the drying stage at
100
◦
C. F0 showed no hysteresis on the isotherms of sorption and desorption unlike the
Coatings 2022,12, 1850 12 of 21
coating samples containing phosphorus. The mechanism of water uptake was changed
with the presence of a P-monomer in the coating. The absence of hysteresis suggested a
plausible surface adsorption mechanism with limited to no bulk absorption. Hence, the
results displayed the influence of adding phosphorus derivatives on the water uptake of
coating films, mainly in the high RH range.
Coatings 2022, 12, x FOR PEER REVIEW 14 of 24
defined in the International Union of Pure and Applied Chemistry nomenclature [42]. F1
displayed a similar water uptake profile to a minor extent, as the mass change at the max-
imum RH reached 5.98% instead of 15.3% for F2. The F2 desorption isotherm did not re-
turn to a null mass change at a 0% RH. The hypothesis was made that the water is still
present in the sample. Further energy seemed to be necessary to remove the bound water.
This latter was removed prior to the DVS test by heating during the drying stage at 100
°C. F0 showed no hysteresis on the isotherms of sorption and desorption unlike the coat-
ing samples containing phosphorus. The mechanism of water uptake was changed with
the presence of a P-monomer in the coating. The absence of hysteresis suggested a plau-
sible surface adsorption mechanism with limited to no bulk absorption. Hence, the results
displayed the influence of adding phosphorus derivatives on the water uptake of coating
films, mainly in the high RH range.
Although those results could appear as a limit for a coating application, the formu-
lated coatings developed in this study are meant for a sealer use. In a complete wood
finishing system, they would benefit from a topcoat applied above. This upper protective
layer will limit water exchange and would be designed to resist abrasion and scratch.
Once integrated in the finishing system, the sealer has a limited contribution to the surface
hardness. Further investigations were thus performed on the coatings and the thermal
stability was first studied.
3.2.4. Coating Thermogravimetric Analysis
The thermal stability of the coating films as well as the TAEP monomer was investi-
gated by thermogravimetric analysis in an inert atmosphere. The mass loss curves and
their derivatives are shown in Figure 7. The main results (T5%, Tmax and the percentages of
residues at 800 °C) are featured in Table 3.
Figure 7. Curves of the thermogravimetric analysis performed under nitrogen and their derivatives
for the TAEP monomer and the coating films with different phosphorus contents.
Figure 7.
Curves of the thermogravimetric analysis performed under nitrogen and their derivatives
for the TAEP monomer and the coating films with different phosphorus contents.
Although those results could appear as a limit for a coating application, the formulated
coatings developed in this study are meant for a sealer use. In a complete wood finishing
system, they would benefit from a topcoat applied above. This upper protective layer
will limit water exchange and would be designed to resist abrasion and scratch. Once
integrated in the finishing system, the sealer has a limited contribution to the surface
hardness. Further investigations were thus performed on the coatings and the thermal
stability was first studied.
3.2.4. Coating Thermogravimetric Analysis
The thermal stability of the coating films as well as the TAEP monomer was investi-
gated by thermogravimetric analysis in an inert atmosphere. The mass loss curves and
their derivatives are shown in Figure 7. The main results (T
5%
, T
max
and the percentages of
residues at 800 ◦C) are featured in Table 3.
Table 3.
Results of thermogravimetric analysis. T
5%
corresponds to the temperature at which 5% of
the sample mass is lost, T
max 1
, T
max 2
and T
max 3
are the temperatures of the degradation rate maxima.
Formulation T5%
(◦C)
Tmax 1
(◦C)
Tmax 2
(◦C)
Tmax 3
(◦C)
Residue at
800 ◦C (%)
F0 295 158 371 418 1 ±1
F1 196 161 357 424 14.7 ±0.5
F2 169 168 331 424 19.6 ±0.5
TAEP 113 132 307 436 30.6 ±0.2
The thermal decomposition of the pure monomer TAEP happened in three distinct
steps, with maximum degradation rates at approximately 160
◦
C, 370
◦
C and 420
◦
C. A
similar behaviour was reported in the literature for the thermogravimetric analysis of
TAEP homopolymer in air [
26
]. Three main decomposition steps were described and
assigned to the decomposition of the phosphate groups (from 160
◦
C to 270
◦
C), the
decomposition of the ester groups (at approximately 330
◦
C) followed by the decomposition
Coatings 2022,12, 1850 13 of 21
of unstable structures in the char (above 500
◦
C). In our study, the analyses showed
that the pristine coating underwent a three-stage decomposition process, with a first
step around 160
◦
C, and then two overlapping steps between 300
◦
C and 475
◦
C. Even
though the F0 formulation was more thermally stable under 400
◦
C compared to F1 and
F2, there was no residue at 800
◦
C. The major F0 degradation range corresponded to a
weight loss of approximately 90%, a percentage greatly higher compared to the ones of
phosphorus-containing formulations. F1 and F2 coatings also displayed a several stages
of decomposition but with better distinguishable steps. F1 coating first had thermal
degradation at a higher temperature range followed by another thermal degradation at
approximately 420
◦
C, which corresponds to the final decomposition of the oligomer and
the monomer. For both phosphorus-containing coatings, it was observed that the thermal
pyrolysis of unstable structures allowed the formation of a stable char above 450
◦
C. The
major mass loss of F2 cured films occurred between 300 ◦C and 360 ◦C. The percentage of
residue at 800 ◦C reached 14.7% for F1 and 19.6% for F2.
Thus, adding phosphorus compounds in the formulation shifts the thermal degrada-
tion to a lower temperature but leads to the formation of stable residues at 800
◦
C. The
development of a char could be a benefit in terms of fire performance; the formation of
such a protective layer was verified with the cone calorimeter tests.
3.3. Coating Adhesion on Wood
Good adhesion between the coating and the wooden substrate is mandatory to ensure
good coating properties and durability [
39
]. Pull-off tests is a common method to assess the
coating adhesion to the substrate that provides a quantitative result. The results of the pull-
off strength of the different coatings applied on wood are presented in Figure 8. During the
tests, only adhesive failure between the substrate and the first coat happened. An increasing
phosphorus content in the coating led to an increasing fibre deposit on the dollies after the
test. Thus, the cohesive strength of the coatings was good and the phosphorus coatings
seemed to offer a better mechanical anchoring with a higher-wood fibres wetting. The
adhesion strength also varied with the phosphorus content. Indeed, while the mean value of
the adhesion strength of the F0 coating was under 1.00 MPa, it attained 1.01 and 1.12 MPa
for F1 and F2, respectively. The statistical analysis conducted on the results revealed
a significant difference in adhesion strength between the coating without phosphorus
monomer and the one with the highest content. Thus, above a certain P-monomer addition
in the formulation, the pull-off strength was slightly enhanced. Phosphorus derivatives are
well-known adhesion promoters [
43
]. For instance, Maege et al. studied the adsorption of
phosphorus derivatives on metallic substrates as an anchor to the coating system, offering
an improved adhesion [
44
]. Wang et al. suggested that a phytic acid-based compound
enhanced the adhesion of UV-curing coating to metal by the formation of P-O-Fe chemical
bonds [
45
]. Even though the presence of phosphorus additives enhancing the adhesion
with wood for coatings or adhesives has been reported in different studies [
15
,
46
,
47
], the
mechanism explaining this improvement is not well detailed.
The difference in pull-off test results could be explained by several factorsincluding the
limited coating penetration into wood [
48
] or the UV coating shrinkage through curing [
49
].
During the photopolymerisation of acrylate systems, the weak intermolecular Van der
Waals interactions in the liquid coating are replaced by strong and short covalent bonds
between the carbon atoms in the solid film [
50
]. The distance between carbon atoms is
reduced, building up internal stress in the coating. The volume contraction induces a
shrinkage that may lead to low coating adhesion and poor mechanical properties [
49
]. In
order to obtain a better understanding, SEM analyses were performed on the sample cross-
sections to observe the wood/coating interface (Figure 9). The F0 sample clearly displayed
the coating detachment from the wooden substrate in different areas. The interface between
the phosphorus coating and wood showed better bonding. The TAEP presence in the
formulation seemed to induce lesser coating shrinkage through photopolymerisation,
enhancing the coating adhesion.
Coatings 2022,12, 1850 14 of 21
Coatings 2022, 12, x FOR PEER REVIEW 16 of 24
formation of P-O-Fe chemical bonds [45]. Even though the presence of phosphorus addi-
tives enhancing the adhesion with wood for coatings or adhesives has been reported in
different studies [15,46,47], the mechanism explaining this improvement is not well de-
tailed.
Figure 8. Pull-off strength of the coatings applied on wood. Letters above the bars correspond to the
groups determined in the Tukey comparison test after the ANOVA analysis (α = 0.05). Groups hav-
ing a letter in common are not significantly different.
The difference in pull-off test results could be explained by several factors including
the limited coating penetration into wood [48] or the UV coating shrinkage through curing
[49]. During the photopolymerisation of acrylate systems, the weak intermolecular Van
der Waals interactions in the liquid coating are replaced by strong and short covalent
bonds between the carbon atoms in the solid film [50]. The distance between carbon atoms
is reduced, building up internal stress in the coating. The volume contraction induces a
shrinkage that may lead to low coating adhesion and poor mechanical properties [49]. In
order to obtain a better understanding, SEM analyses were performed on the sample
cross-sections to observe the wood/coating interface (Figure 9). The F0 sample clearly dis-
played the coating detachment from the wooden substrate in different areas. The interface
between the phosphorus coating and wood showed better bonding. The TAEP presence
in the formulation seemed to induce lesser coating shrinkage through photopolymerisa-
tion, enhancing the coating adhesion.
Figure 8.
Pull-off strength of the coatings applied on wood. Letters above the bars correspond to
the groups determined in the Tukey comparison test after the ANOVA analysis (
α
= 0.05). Groups
having a letter in common are not significantly different.
Coatings 2022, 12, x FOR PEER REVIEW 17 of 24
Figure 9. SEM images of the wood/coating interface, F0 (a), F1 (b) and F2 (c). Arrows show coating
detachments of few microns wide from wood.
3.4. Fire Performance of the Coated Wood Samples
Heat release curves are displayed in Figure 10 and key values are summarised in
Table 4. All coated panels present a heat release curve with two peaks, similar to what is
usually observed in the literature for virgin wood [51]. The first peak is attained before
charring. The heat release rate then decreases as a protective layer, i.e. a char, is formed.
Then, the HRR curve illustrates the gradual burning through the thickness of the wood
sample after the formation of the initial char. Once the carbonaceous protective layer
crakes, a second HRR rise happens. The second peak also corresponds to the increased
rate of volatile formation prior to the end of the flame burning [52].
(a)
(b)
(c)
Figure 9.
SEM images of the wood/coating interface, F0 (
a
), F1 (
b
) and F2 (
c
). Arrows show coating
detachments of few microns wide from wood.
Coatings 2022,12, 1850 15 of 21
3.4. Fire Performance of the Coated Wood Samples
Heat release curves are displayed in Figure 10 and key values are summarised in
Table 4. All coated panels present a heat release curve with two peaks, similar to what is
usually observed in the literature for virgin wood [
51
]. The first peak is attained before
charring. The heat release rate then decreases as a protective layer, i.e. a char, is formed.
Then, the HRR curve illustrates the gradual burning through the thickness of the wood
sample after the formation of the initial char. Once the carbonaceous protective layer crakes,
a second HRR rise happens. The second peak also corresponds to the increased rate of
volatile formation prior to the end of the flame burning [52].
Coatings 2022, 12, x FOR PEER REVIEW 18 of 24
Figure 10. Cone calorimeter heat release rate curves of the coated wood samples.
Table 4. Main cone calorimeter results of the coated wood samples.
Parameter
F0
F1
F2
Phosphorus coating content * (wt%)
0.0
1.7
3.4
TTI (s)
71 ± 2
77 ± 9
90 ± 20
pHRR (kW·m−2)
390 ± 10
340 ± 10
340 ± 10
THR (MJ·m−2)
47 ± 1
44 ± 2
42 ± 1
Residue (wt%)
7.6 ± 0.3
9.8 ± 0.6
10.4 ± 0.6
* Phosphorus coating contents were calculated based on the phosphorus content value (7.89 wt%)
of the TAEP monomer obtained by ICP-OES analysis.
F0 coating cracked within a few seconds after exposure to the heat flux. The coating
delaminated from the surface, exposing the wooden substrate to the flame. A high first
heat release rate peak was rapidly reached for the F0 sample. A second peak was observed
attaining a value of 390 kW·m −2. The higher the value of the HHR first peak for the F0
coating compared to the other samples was attributed to the greater organic coating con-
tribution to the burning. The phosphorus coatings also showed some delamination but to
a lesser extent compared to F0. This difference in coating adhesion to wood was already
highlighted with pull-off tests. A good coating adhesion is critical in the beginning of the
cone calorimeter test and decisive for the fire behaviour of the material. Some cracks also
appeared on F1 and F2 coating surface after the ignition. Similarly to what was observed
for the F0 coating, the HRR curve of F1-coated wood samples presented a first peak but
with a lower value, suggesting the formation of a protective char layer. The heat transfer
and fuel supply to the flame were limited, slowing down the pyrolysis process. Cracks in
the protective layer appeared, allowing the flame to reach the virgin wood. An increase
in the pyrolysis then occurred, leading to a second heat release rate rise. For the highest
phosphorus-FR-containing film (F2 coating), the curve depression was considerably flat-
tened. It was assumed that the protective layer is formed more efficiently for the F2 sample
as a plateau rather than a peak was observed on the HRR curve in the early stage of the
test. In the case of phosphorus-containing coatings, the pHRR only reached 340 kW·m −2
and was delayed compared to F0. Adding a phosphorus monomer enhanced the residual
Figure 10. Cone calorimeter heat release rate curves of the coated wood samples.
Table 4. Main cone calorimeter results of the coated wood samples.
Parameter F0 F1 F2
Phosphorus coating content * (wt%) 0.0 1.7 3.4
TTI (s) 71 ±2 77 ±9 90 ±20
pHRR (kW·m−2)390 ±10 340 ±10 340 ±10
THR (MJ·m−2)47 ±1 44 ±2 42 ±1
Residue (wt%) 7.6 ±0.3 9.8 ±0.6 10.4 ±0.6
* Phosphorus coating contents were calculated based on the phosphorus content value (7.89 wt%) of the TAEP
monomer obtained by ICP-OES analysis.
F0 coating cracked within a few seconds after exposure to the heat flux. The coating
delaminated from the surface, exposing the wooden substrate to the flame. A high first
heat release rate peak was rapidly reached for the F0 sample. A second peak was observed
attaining a value of 390 kW
·
m
−2
. The higher the value of the HHR first peak for the
F0 coating compared to the other samples was attributed to the greater organic coating
contribution to the burning. The phosphorus coatings also showed some delamination
but to a lesser extent compared to F0. This difference in coating adhesion to wood was
already highlighted with pull-off tests. A good coating adhesion is critical in the beginning
of the cone calorimeter test and decisive for the fire behaviour of the material. Some
cracks also appeared on F1 and F2 coating surface after the ignition. Similarly to what
was observed for the F0 coating, the HRR curve of F1-coated wood samples presented
a first peak but with a lower value, suggesting the formation of a protective char layer.
Coatings 2022,12, 1850 16 of 21
The heat transfer and fuel supply to the flame were limited, slowing down the pyrolysis
process. Cracks in the protective layer appeared, allowing the flame to reach the virgin
wood. An increase in the pyrolysis then occurred, leading to a second heat release rate
rise. For the highest phosphorus-FR-containing film (F2 coating), the curve depression
was considerably flattened. It was assumed that the protective layer is formed more
efficiently for the F2 sample as a plateau rather than a peak was observed on the HRR
curve in the early stage of the test. In the case of phosphorus-containing coatings, the
pHRR only reached
340 kW·m−2
and was delayed compared to F0. Adding a phosphorus
monomer enhanced the residual mass percentage as well as reduced the THR, suggesting
an improved wood charring behaviour. The time to ignition also varied with the FR loading
with an upward tendency.
A reduction of 13% in the pHRR could appear as a moderate improvement. How-
ever, adding a phosphorus monomer positively affected other parameters such as the
percentage of residues after the test. Wang et al. also reported a pHRR decrease of approxi-
mately 10% with their best treatment obtained in the cone calorimeter test performed at
50 kW
·
m
−2
[
15
]. The wood coatings reported in this study contained the following FR at
different ratios: a multifunctional bio-mercaptan of castor oil grafted thiol, 2,4,6-trimethyl-
2,4,6-trivinylcyclotrisilazane and an organic phosphorus compound. The UV-curable
coating was applied at 180
µ
m (versus 50
µ
m in the present study) on 4 mm thick Chinese
fir samples. The pHRR curve followed a reverse tendency compared to our study, with a
higher first peak compared to the second one. Higher pHRR decreases were observed for a
non UV-curable waterborne intumescent wood coating [
53
] or for coating applied on wood
with a thicker layer [
54
]. For the first study, Song et al. obtained a clear pHRR decrease of
approximately 40% and a delayed TTI compared to pure wood, a 4 mm thick poplar panel.
All the pHRR of the samples treated with the different intumescent coatings ranged from
140 kW
·
m
−2
to 190 kW
·
m
−2
after the cone calorimeter test. In the second study, epoxy
coatings were applied on a poplar wood sample at a 5 mm thick layer. The authors reported
a pHRR reduction of 20% with the addition of a phosphaphenanthrene-containing epoxy
co-curing agent in the coating formulation compared to the epoxy coating reference.
The cone calorimeter residues were collected and analysed to better comprehend the
charring mechanism. SEM analyses were performed on the residues collected after the test
to confirm the action of phosphate moieties in the condensed phase (Figure 11). The mass
percentages of different elements obtained from the EDS analysis performed on the same
residues are gathered in Table 5.
Table 5.
Elemental composition analysis performed on different areas (identified on Figure 11) of the
cone calorimeter residues.
Analysis Area C
(wt%) O (wt%) P
(wt%)
Ca
(wt%)
Mg
(wt%)
Mn
(wt%)
K
(wt%)
F0—Area 1 65.45 27.33 0.31 4.41 1.08 0.98 0.44
F0—Area 2 12.28 51.08 1.59 21.95 4.84 4.85 3.40
F1—Area 3 81.69 16.49 1.46 0.35 - - -
F1—Area 4 81.16 17.24 1.44 0.17 - - -
F2—Area 5 76.47 21.04 2.14 0.35 - - -
F2—Area 6 80.77 16.44 2.11 0.52 0.15 - -
F0 residues displayed a very fragile fibrous structure with no visible coating deposit.
No charring was observed, only ashes were formed. It is similar to wood sample morphol-
ogy after being exposed to a flame as reported in the literature [
55
]. On the contrary, the
flame-retarded samples clearly displayed some wooden charred structure demonstrating
that a protective mechanism occurred. For both F1 and F2 samples, high temperature-
resisting residues of the coating were noticeable. In the case of the F1 sample, a partial
delamination of the coating was observed, revealing a thick char underneath. This solid
structure is present on the right-hand side of Figure 11b. Fractures in the F1 residues were
Coatings 2022,12, 1850 17 of 21
also visible. They went through the coating and the substrate. F2 residues also displayed
a thick char formation. Almost no coating detachment was noticed but cracks were still
observed. Interestingly, most of the cracks did not go through the substrate either. Indeed,
Figure 11d revealed that most F2 coating fractures were protected by an underneath layer.
The F2 burnt sample showed a surface morphology with hollowed areas and trapped
bubbles underneath the top layer.
Coatings 2022, 12, x FOR PEER REVIEW 20 of 24
Figure 11. SEM images of cone calorimeter residues of F0 (a), F1 (b) and F2 (c,d).
Table 5. Elemental composition analysis performed on different areas (identified on Figure 11) of
the cone calorimeter residues.
Analysis Area
C
(wt%)
O (wt%)
P
(wt%)
Ca
(wt%)
Mg
(wt%)
Mn
(wt%)
K
(wt%)
F0—Area 1
65.45
27.33
0.31
4.41
1.08
0.98
0.44
F0—Area 2
12.28
51.08
1.59
21.95
4.84
4.85
3.40
F1—Area 3
81.69
16.49
1.46
0.35
-
-
-
F1—Area 4
81.16
17.24
1.44
0.17
-
-
-
F2—Area 5
76.47
21.04
2.14
0.35
-
-
-
F2—Area 6
80.77
16.44
2.11
0.52
0.15
-
-
EDS analyses further endorsed the action of phosphorus compounds participating in
the char formation. Whereas the analysis of the F0 residues revealed the presence of typi-
cal elements found in wood ash, the elemental composition significantly varied when a
phosphorus-containing coating was applied on the wood. Misra et al. observed that the
wood ash at 600 °C was mainly composed of calcium, potassium and magnesium, apart
from carbon and oxygen elements [56]. Phosphorus, sulphur and manganese were also
present to a minor extent. Wood decomposition forms calcium carbonate and oxide [57].
High O wt% and Ca wt% for F0 endorsed the presence of calcium derivatives. F1 and F2
surface analysis demonstrated higher C and P contents. The phosphorus coming from the
FR coating application was still present in the residues after the cone calorimeter test. As
expected, a higher P content was observed for F2 compared to F1. A significant amount
of phosphorus induces an active role of the FR in a condensed phase mechanism. It is
Area 1
Area 2
(a)
(b)
Area 4
Area 3
(c)
Area 6
Area 5
(d)
Figure 11. SEM images of cone calorimeter residues of F0 (a), F1 (b) and F2 (c,d).
Thus, the presence of a protective layer after the cone calorimetry tests on the residues
of wood samples, either coated with F1 or F2 formulation, validates an action of the
phosphate moieties in the condensed phase. The TAEP addition to the coating formulation
helped the char formation, increasing the mass residue. An insulating barrier is formed,
protecting the underneath substrate from fire, and preventing gas exchange between the
condensed phase and the flame.
EDS analyses further endorsed the action of phosphorus compounds participating
in the char formation. Whereas the analysis of the F0 residues revealed the presence of
typical elements found in wood ash, the elemental composition significantly varied when a
phosphorus-containing coating was applied on the wood. Misra et al. observed that the
wood ash at 600
◦
C was mainly composed of calcium, potassium and magnesium, apart
from carbon and oxygen elements [
56
]. Phosphorus, sulphur and manganese were also
present to a minor extent. Wood decomposition forms calcium carbonate and oxide [
57
].
High O wt% and Ca wt% for F0 endorsed the presence of calcium derivatives. F1 and F2
surface analysis demonstrated higher C and P contents. The phosphorus coming from the
FR coating application was still present in the residues after the cone calorimeter test. As
expected, a higher P content was observed for F2 compared to F1. A significant amount of
Coatings 2022,12, 1850 18 of 21
phosphorus induces an active role of the FR in a condensed phase mechanism. It is worth
mentioning that even though the P content of area 2 of F0 sample and the one of F1 sample
were in the same range, these were not comparable as the percentages of the other elements
were completely different. EDS analysis gives the relative elemental composition of a local
sample area based on the total detected elements in it. While F0 corresponded to an ashes
area with a C content under 15%, the F1 sample charred, resulting in a high C content,
above 80%.
We may conclude that a decrease in the pHRR combined with an increase in the
residual mass indicates an effective action of the TAEP addition regarding flame retardancy.
The cone calorimeter tests along with the observation of the residues also suggested a
difference in coating adhesion depending on the phosphorus rate in the formulation. With
a higher phosphorus content, the least coating delamination occurred, contributing to the
improvement of the fire behaviour of the coated wood.
4. Conclusions
High-solid-content transparent UV-curable coatings were prepared at different TAEP
percentages in an acrylate-based formulation. Coatings were applied on wood panels. The
photopolymerisation kinetics was monitored by photo-DSC. It was shown that adding
the phosphorus monomer did not impact the UV-curing behaviour as the conversion of
the acrylate group was in the same range, i.e., over 65%. A change in coating hardness
was observed and attributed to the fact that TAEP brought flexibility to the coating films.
This study also showed that P-containing coatings displayed a higher water sorption for
high relative humidity. The issue related to water affinity could be easily lowered by
integrating the formulation as a sealer coat in a prefinished wood flooring system. The
presence of the phosphorus monomer at the highest content significantly improved the
coating adhesion on the wood. The wood coating fire efficacy was evaluated by cone
calorimetry. A decreased pHRR as well as an enhanced residue percentage were obtained
for all the phosphorus-containing coatings. SEM and EDS analyses performed on the
collected residues confirmed the formation of a solid protective structure and the pres-
ence of phosphorus in the flame-retarded samples. The phosphorus FR had an effective
action in the condensed phase, improving the fire retardancy of the coated wood. The
formulation containing approximately 40% of TAEP clearly displayed the best FR perfor-
mances compared to the non-FR coating. Furthermore, the major expected properties of a
sealer coating were positively assessed. This study thus demonstrates the high potential
of phosphorus-containing UV-curable acrylate system to improve the fire behaviour of
wood flooring. Further investigations could include the introduction of another FR retar-
dant in the formulation. Nitrogen or silicon compounds have demonstrated a synergistic
behaviour along with the phosphorus FR. The