Core-shell structure design of pulverized expandable graphite particles and their application in flame-retardant rigid polyurethane foams

Study on the Flame Retardancy of Rigid Polyurethane Foam with Phytic Acid-Functionalized Graphene Oxide

A rigid polyurethane foam (RPUF) composite was prepared by compounding phytic acid (PA)-functionalized Graphite oxide (PA-GO) with flame-retardant poly (Ammonium phosphate) (APP) and expandable graphite (EG). The effects of PA-GO on the thermal, flame-retardant, and mechanical properties of RPUF were studied using a thermogravimetric analyzer, a limiting oxygen index (LOI) tester, a UL-94 vertical combustion tester, a cone calorimeter, scanning electron microscopy, and a universal tensile testing machine. The results indicated that there was a significant synergistic flame-retardant effect between PA-GO and the intumescent flame retardants (IFR) in the RPUF matrix. Compared with RPUF-1, the addition of 0.3 wt% PA-GO could increase LOI from 25.7% to 26.5%, increase UL-94 rating from V-2 to V-0, and reduce the peak heat release rate (PHRR) and total heat release rate (THR) by 28.5% and 22.2%, respectively. Moreover, the amount of residual char increased from 22.2 wt% to 24.6 wt%, and the char layer was continuous and dense, with almost no holes. Meanwhile, the loss of mechanical properties was apparently lightened.

Bio-Based Rigid Polyurethane Foams Modified with C-MOF/MWCNTs and TBPBP as Building Insulation Materials: Synergistic Effect and Corresponding Mechanism for Enhancing Fire and Smoke Safety

Rigid polyurethane foams (RPUFs) as building insulation materials quickly burn and release a lot of heat, smoke, and carbon monoxide, and cause human safety risk and severe environmental pollution. To mitigate these disadvantages, MOF/MWCNTs were fabricated via mixing Cu ions' partly substituted framework of ZIF-67 and MWCNTs, and further calcinated MOF/MWCNTs (C-MOF/MWCTs) was newly generated by calcinating MOF/MWCNTs in air. Then, MOF/MWCNTs and C-MOF/MWCNTs were respectively employed together with a phosphorus-nitrogen-containing reactive flame retardant (TBPBP) to prepare renewable bio-based rigid polyurethane foam, including RPUF-T/MOF/MWCNTs 2 and RPUF-T/C-MOF/MWCNTs 2. The characterization results showed that RPUF-T/C-MOF/MWCNTs 2 had better performance than RPUF-T/MOF/MWCNTs 2 and neat RPUF. Compared to neat RPUF, the compressive strength, limiting oxygen index value, and the mass char residue in cone calorimetry test of RPUF-T/C-MOF/MWCNTs 2, respectively, were increased by 105.93%, 46.35%, and 347.32%; meanwhile, the total heat release rate, total smoke production, total carbon monoxide product, and total carbon dioxide product were reduced by 47.97%, 50.46%, 41.38%, 43.37%, respectively. This study provides a referable method for preparing RPUFs with good physical properties, fire, and smoke safety, which is favorable for human safety and environmental protection as new building insulation materials.

A Systematic Review and Bibliometric Analysis of Flame-Retardant Rigid Polyurethane Foam from 1963 to 2021

Flame-retardant science and technology are sciences developed to prevent the occurrence of fire, meet the needs of social safety production, and protect people's lives and property. Rigid polyurethane (PU) is a polymer formed by the additional polymerization reaction of a molecule with two or more isocyanate functional groups with a polyol containing two or more reactive hydroxyl groups under a suitable catalyst and in an appropriate ratio. Rigid polyurethane foam (RPUF) is a foam-like material with a large contact area with oxygen when burning, resulting in rapid combustion. At the same time, RPUF produces a lot of toxic gases when burning and endangers human health. Improving the flame-retardant properties of RPUF is an important theme in flame-retardant science and technology. This review discusses the development of flame-retardant RPUF through the lens of bibliometrics. A total of 194 articles are analyzed, spanning from 1963 to 2021. We describe the development and focus of this theme at different stages. The various directions of this theme are discussed through keyword co-occurrence and clustering analysis. Finally, we provide reasonable perspectives about the future research direction of this theme based on the bibliometric results.

Nanocomposites of Rigid Polyurethane Foam and Graphene Nanoplates Obtained by Exfoliation of Natural Graphite in Polymeric 4,4′-Diphenylmethane Diisocyanate

The influence of graphene nanoplates (GNPs) obtained by the ecofriendly exfoliation of natural graphite has been addressed on the mechanical and thermal insulating properties of rigid polyurethane foams (RPUFs). Few-layer GNPs with few defects were prepared in polymeric 4,4′-diphenylmethane diisocyanate (pMDI) under ultrasonication to obtain a GNP/pMDI dispersion. GNP/pMDI dispersions with different GNP concentrations were used to prepare RPUF nanocomposites via in situ polymerization. An important finding is that the GNP/pMDI dispersion exhibits lyotropic liquid crystalline behavior. It was found that the unique orientation of GNPs above the concentration of 0.1 wt% in the dispersion affected the mechanical and thermal insulation properties of the RPUF nanocomposites. GNP/RPUF nanocomposites with GNP concentrations at 0.2 wt% or more showed better thermal insulating properties than neat RPUF. The lyotropic liquid crystalline ordering of GNPs provides stable nucleation for bubble formation during foaming and prevents bubble coalescence. This decreases the average cell size and increases the closed cell content, producing GNP/RPUF nanocomposites with low thermal conductivity. Furthermore, GNPs incorporated into RPUF act as a barrier to radiant heat transfer through the cells, which effectively reduces the thermal conductivity of the resulting nanocomposites. It is expected that the nanocomposite of RPUF investigated in this study can be applied practically to improve the performance of thermal insulation foams.

Effect of flame retardants on mechanical and thermal properties of bio-based polyurethane rigid foams

A soy oil-based polyol (HSBP) was synthesized from epoxidized soy oil through a ring-opening reaction with distilled water. A phosphorus-containing flame retardant (DOPO–HSBP) was synthesized through the reaction of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) and HSBP. A nitrogen-containing flame retardant (T–D) was prepared by the reaction of diethanolamine with glycol diglycidyl ether. The structures of HSBP, DOPO–HSBP, and T–D were characterized by Fourier transform infrared spectroscopy (FT-IR) and nuclear magnetic resonance (¹H NMR). The flame-retardant rigid polyurethane foam (PPUFs and NPUFs) was prepared successfully by mixing HSBP, DOPO–HSBP, and T–D. The effects of DOPO–HSBP content on the mechanical, thermal, and flame-retardant properties of PPUFs and NPUFs were investigated by tensile tests, thermogravimetric analyses (TGA), limiting oxygen index (LOI), and UL-94 vertical burning level. The morphology of PPUFs and NPUFs was studied via scanning electron microscopy (SEM). With the increase in the percentage of DOPO–HSBP added, the flame retardant property of rigid polyurethane foam (RPUF) was greatly improved. When the phosphorus-containing flame retardant DOPO–HSBP was added to 50% of the RPUF with the nitrogen-containing flame retardant T–D, the LOI value of the foam increased from 18.3 to 25.5, and the UL-94 result was classified as “V-0” with almost no effect on the mechanical properties of the RPUF. The results showed that the phosphorus and nitrogen synergistic flame retardants of DOPO–HSBP and T–D can endow excellent flame retardant properties to RPUF without affecting its mechanical properties.

A vegetable oil-based polyurethane rigid foam containing a phosphorus–nitrogen dualflame retardant system was prepared, and the foam exhibited not only excellent flame retardant properties but also good mechanical properties.

Microstructure design of polypropylene/expandable graphite flame retardant composites toughened by the polyolefin elastomer for enhancing its mechanical properties

The enhanced toughness of flame-retardant polymer composites is still a big challenge due to the deterioration of their mechanical properties. In this work, polypropylene (PP)/nanohybrid expandable graphite (nEG) flame-retardant composites toughened by octene-ethylene copolymer (POE) were fabricated for obtaining good mechanical properties and flame retardancy. The structure, rheological and crystallization behaviors, morphology, flame retardancy, and mechanical property of PP/nEG/POE composites with different contents of POE were investigated. Results show that the elongation at break and impact strength of PP composites were significantly improved due to the incorporation of POE. The elongation at break and notched impact strength of toughened PP composites with only 20% POE were increased to 521.6% and 22.9 kJ m^-2 from 16.1% and 9.3 kJ m^-2 for untoughened PP composites, respectively. The scanning electron micrography (SEM) images showed that POE droplets were dispersed finely and uniformly in the PP matrix, exhibiting a typical two-phase structure. Additionally, the interfacial adhesion between the matrix and inorganic particles was enhanced due to the addition of POE. The rheological behaviors of PP composites showed improved elasticity and longer relaxation times, and a stress-yield behavior appeared with the addition of POE. The interfacial interaction in PP composites was enhanced and the formation of an interparticle network was further proved. Additionally, the toughened PP/nEG20 composites with different contents of POE exhibited excellent flame retardancy. Therefore, the toughened flame-retardant PP composites should possess a wider range of application potential.

Synergistic Effects of Flame Retardants on the Flammability and Foamability of PS Foams Prepared by Supercritical Carbon Dioxide Foaming

Halogen-free flame-retardant polystyrene (PS) foams prepared by supercritical carbon dioxide (SC-CO₂) foaming have been achieved. The flame-retardants include expandable graphite (EG) and melamine phosphate (MP), and their influence on the foamability, decomposition behavior, fire performance, and mechanical properties of PS foams were investigated. It has been shown that flame retardants can generate inert gases and catalyze the char formation from PS, and the formed thick char layer with a notable barrier property can greatly decrease the heat release of PS foams. The addition of triphenyl phosphate (TPP) or hexaphenoxycyclotriphosphazene (HPCTP), which acts as a flame-retardant plasticizer, can obviously improve the foamability and fire performance of the foams. TPP or HPCTP can generate active phosphorous species and phenoxyl radicals to enhance the gas phase flame-retardant effect; therefore, the flame-retarded PS foams (with 25 wt % MP/EG) achieve HF1 and V-0 ratings, with limiting oxygen index (LOI) values of 30.1 or 29.6%, respectively. The numerical assessment of synergistic effects of TPP and HPCTP on further enhancing flame retardancy of PS foams has been provided by the microcalorimeter (MCC) test. Further X-ray photoelectron spectroscopy (XPS) investigation on char residues of PS foams demonstrates the formation of the P-O-C and other stable structures.

Efficient organic–inorganic intumescent interfacial flame retardants to prepare flame retarded polypropylene with excellent performance

An efficient and simple approach for the preparation of organic–inorganic intumescent interfacial flame retardants, aiming at enhancing the flame-retardant efficiency and interfacial adhesion between matrix and flame retardants was presented.

Flame retardancy and smoke suppression properties of flexible polyurethane foams containing an aluminum phosphate microcapsule

A novel aluminum phosphate (ALP) microcapsule was synthesized with the aim of enhancing the flame retardancy and smoke suppression properties of flexible polyurethane (PU) foams.

Environmentally Friendly Flame-Retardant and Its Application in Rigid Polyurethane Foam

A novel Flame-Retardant N-(P,P′-diphenyl) phosphorus-based-(3-triethoxysilicon) propylamine (DPTP) was synthesized in this study. The impact of DPTP on the mechanical properties, thermal stability, and flame retardancy of rigid polyurethane foam (RPUF) was studied. The addition of DPTP to RPUF can significantly reduce the undesirable thermal effects and smoke density during combustion, as well as increasing the limiting oxygen index. Compared with pure RPUF, the peak heat release rate of RPUF containing 10 phr of DPTP decreased by 39.4%, while its peak smoke production rate decreased by 49.9%. However, it was also found that the addition of DPTP reduced the compressive strength of RPUF.