Abstract
This study aims to develop a recyclable, economical, and flame-retardant composite material using polypropylene, beech flour, tetrabromobisphenol A bis (TBBPA), and antimony trioxide (ATO). Flame-retardant additives (TBBPA and ATO) were initially added into polypropylene at different rates, and masterbatch (MB) samples were produced by the extrusion method. Subsequently, different percentages of wood flour (10%, 15%, 20%, 25%, and 30%) along with 60% MB were added to the polypropylene to create wood-polymer composites (WPC) using the injection method. The TBBPA, ATO, and wood flour were introduced through side-feeding hoppers during injection to ensure a homogeneous distribution within the WPC. Physical, thermal, and mechanical tests were conducted on the WPC samples. Additionally, TGA, FTIR, and SEM analyses were performed. The results indicated that the optimal ratios for TBBPA and ATO additives were 20% and 10%, respectively. It was observed that increasing the wood flour content in the WPC samples led to enhanced density, water absorption, hardness, impact, and abrasion resistance. Conversely, MFI, bending strength, and tensile strength decreased with higher wood flour content. It was observed that WPC samples exhibited flame resistance up to 725 °C. The produced WPC materials can be used in flooring applications, interior furniture, decorative wall panels, and aesthetic structural elements due to their fire behavior, good mechanical properties, low water-absorption rates, and aesthetic appearance.