Phosphorous-filled nanobrick wall multilayer thin film eliminates polyurethane melt dripping and reduces heat release associated with fire

Advanced Flame-Retardant Methods for Polymeric Materials

Most organic polymeric materials have high flammability, for which the large amounts of smoke, toxic gases, heat, and melt drips produced during their burning cause immeasurable damages to human life and property every year. Despite some desirable results having been achieved by conventional flame-retardant methods, their application is encountering more and more difficulties with the ever-increasing high flame-retardant requirements such as high flame-retardant efficiency, great persistence, low release of heat, smoke, and toxic gases, and more importantly not deteriorating or even enhancing the overall properties of polymers. Under such condition, some advanced flame-retardant methods have been developed in the past years based on "all-in-one" intumescence, nanotechnology, in situ reinforcement, intrinsic char formation, plasma treatment, biomimetic coatings, etc., which have provided potential solutions to the dilemma of conventional flame-retardant methods. This review briefly outlines the development, application, and problems of conventional flame-retardant methods, including bulk-additive, bulk-copolymerization, and surface treatment, and focuses on the raise, development, and potential application of advanced flame-retardant methods. The future development of flame-retardant methods is further discussed.

Stiffness enhancement of magnetorheological foam by structural modification using silica nanoparticles additive

Magnetorheological (MR) foam is a newly developed porous smart material that is able to change its properties continuously, actively, and reversibly in response to controllable external magnetic stimuli. Unfortunately, the stiffness or also known as storage modulus of MR foam is still rather low and insufficient, in the range of below 100 kPa only, due to weak interparticle interaction between CIPs and the foam matrix, which consequently restricts the potential of MR foam to be used in future sensor applications or in other semi-active devices. Therefore, the aim of this research is to enhance the structural and storage modulus of MR foam by adding silica nanoparticles as an additive. Consequently, MR foam samples with different compositions of silica nanoparticles in the range of 0–5 wt% were prepared via an in situ method. The rheological properties were tested under an oscillatory shear mode with the absence and presence of magnetic fields using a rheometer, with the input parameters of strains between 0.001% and 10% and range of magnetic flux density between 0 and 0.73 T for a magnetic field sweep test. The rheological findings show that with the addition of silica nanoparticles, particularly at 4 wt%, have enhanced the storage modulus of MR foam by 260%, which attributed to the highest stiffness from 45 to 162 kPa. Meanwhile, the change of storage modulus under the influence of magnetic fields (0 T–0.73 T) somehow showed small increment, about ∆1 kPa for each concentration of silica nanoparticles in MR foams, due to non-magnetic behavior of silica. The morphological characteristics of MR foams were described by an elemental analysis carried out by a using variable pressure scanning electron microscope (VPSEM) equipped with energy dispersive x-ray spectroscopy (EDX). The micrographs demonstrated large open-cell pores for MR foam, while MR foam with silica nanoparticles exhibited more closed-cell pores, associated with the enhancement of its storage modulus. It indicates that the silica nanoparticles have encouraged well dispersion of the particles in the foam matrix, which improved and strengthened the microstructure of MR foams through formation of silane coupling bonds of silica in the filler-matrix structure. Overall, incorporation of silica nanoparticles as an additive in the MR foam could provide advantage in enhancing the structure and mechanical properties of MR foam, for various future smart devices.

Phytic Acid-Iron/Laponite Coatings for Enhanced Flame Retardancy, Antidripping and Mechanical Properties of Flexible Polyurethane Foam

The use of flexible polyurethane foam (FPUF) is severely limited due to its flammability and dripping, which can easily cause major fire hazards. Therefore, choosing an appropriate flame retardant to solve this problem is an urgent need. A coating was prepared on the FPUF surface by dipping with phytic acid (PA), Fe2(SO4)3·xH2O, and laponite (LAP). The influence of PA-Fe/LAP coating on FPUF flame-retardant performance was explored by thermal stability, flame retardancy, combustion behavior, and smoke density analysis. FPUF/PA-Fe/LAP has a good performance in the small fire test, which can pass the UL-94 V-0 rating and the limiting oxygen index reaches 24.5%. Meanwhile, the peak heat release rate values and maximum smoke density of FPUF/PA-Fe/LAP are reduced by 38.7% and 38.5% compared with those of neat FPUF. After applying PA-Fe/LAP coating, the value of fire growth rate index decreases from 10.5 kW/(m2·s) to 5.1 kW/(m2·s), dramatically reducing the fire risk. Encouragingly, the effect of PA-Fe/LAP coating on cyclic compression and permanent deformation is small, which is close to that of neat FPUF. This work provides an effective strategy for making a flame-retardant FPUF with antidripping and keeping mechanical properties.

Experimental and numerical perspective on the fire performance of MXene/Chitosan/Phytic acid coated flexible polyurethane foam

Recent discoveries of two-dimensional transitional metal based materials have emerged as an excellent candidate for fabricating nanostructured flame-retardants. Herein, we report an eco-friendly flame-retardant for flexible polyurethane foam (PUF), which is synthesised by hybridising MXene (Ti[Formula: see text]) with biomass materials including phytic acid (PA), casein, pectin, and chitosan (CH). Results show that coating PUFs with 3 layers of CH/PA/Ti[Formula: see text] via layer-by-layer approach reduces the peak heat release and total smoke release by 51.1% and 84.8%, respectively. These exceptional improvements exceed those achieved by a CH/Ti[Formula: see text] coating. To further understand the fundamental flame and smoke reduction phenomena, a pyrolysis model with surface regression was developed to simulate the flame propagation and char layer. A genetic algorithm was utilised to determine optimum parameters describing the thermal degradation rate. The superior flame-retardancy of CH/PA/Ti[Formula: see text] was originated from the shielding and charring effects of the hybrid MXene with biomass materials containing aromatic rings, phenolic and phosphorous compounds.

Effects of Graphite Oxide Nanoparticle Size on the Functional Properties of Layer-by-Layer Coated Flexible Foams

The exploitation of self-assembled coatings comprising graphite oxide (GO) nanoplates has been recently demonstrated as a promising route to improve the fire safety of flexible polyurethane (PU) foams. However, limited knowledge has been gathered on the correlations between the physical and chemical properties of different GO grades and the performance obtained in this application. This work addresses the effects of the nanoparticle dimensions on the layer-by-layer (LbL) assembly and flame-retardant properties of GO-based coatings deposited on PU foams. To this aim, three GO bearing different lateral sizes and thicknesses were selected and LbL-assembled with chitosan (CHIT). Coating growth and morphology were evaluated by FTIR and FESEM, respectively. The resulting CHIT/GO assemblies were demonstrated to be capable of slowing down the combustion of the PU both in flammability and forced combustion tests. In addition, compressive stress/strain tests pointed out that the LbL-coated foams (22-24 kg/m³) could easily replace denser commercial PU foam (40-50 kg/m³) with weight reduction potentials in the transport field. These results are correlated with the properties of the employed GO. The production of assemblies characterized by a high density of CHIT/GO interfaces is identified as the main parameter controlling the FR efficiency and the mechanical properties of the coatings.

A fully bio-based coating made from alginate, chitosan and hydroxyapatite for protecting flexible polyurethane foam from fire

The present study reports the successful synthesis of the flame-retardant and smoke-suppressant flexible polyurethane foam (FPUF) through a fully bio-based coating. Hydroxyapatite (HAP) is added to the solutions containing sodium alginate (SA) and chitosan (CH), respectively, to create negative and positive polyelectrolytes for Layer-by-Layer (LbL) assembly. The influence of the solution concentrations and bilayers numbers deposited on the flame-retardant and mechanical properties of FPUF samples is investigated systematically. Benefitting from the presence of such a fully bio-based coating, the resultant FPUF affords excellent smoke-suppressant and flame-retardant features. In particular, the FPUF coated by 9 bilayers of HAP-SA/HAP-CH exhibits significantly declined peak heat release rate, total release rate and smoke production release by 77.7 %, 56.5 % and 53.8 %, respectively. The compression test verifies the coated FPUFs exhibit lower recovery properties compared with the uncoated one. These results demonstrate that a green and cost-effective strategy is provided for producing flame-retardant, anti-dripping and smoke-suppressant FPUFs.

MXene/chitosan nanocoating for flexible polyurethane foam towards remarkable fire hazards reductions

MXene/chitosan nanocoating for flexible polyurethane foam (PUF) was prepared via layer-by-layer (LbL) approach. MXene (Ti₃C₂) ultra-thin nanosheets were obtained through etching process of Ti₃AlC₂ followed by exfoliation. The deposition of MXene/chitosan nanocoating was conducted by alternatingly immersing the PUF into a chitosan solution and a Ti₃C₂ aqueous dispersion, which resulted in different number of bilayers (BL) ranging from 2, 5 and 8. Owing to the utilization of ultra-thin Ti₃C₂ nanosheets, the weight gain was only 6.9% for 8 BL coating of PUF, which minimised the unfavourable impact on the intrinsic properties of PUF. The Ti₃C₂/chitosan coating significantly reduced the flammability and smoke releases of PUF. Compared with unmodified PUF, the 8 BL coating reduced the peak heat release rate by 57.2%, alongside with a 65.5% reduction in the total heat release. The 8 BL coating also showed outstanding smoke suppression ability with total smoke release decreased by 71.1% and peak smoke production rate reduced by 60.3%, respectively. The peak production of CO and CO₂ gases also decreased by 70.8% and 68.6%, respectively. Furthermore, an outstanding char formation performance of 37.2 wt.% residue was obtained for 8 BL coated PUF, indicating the excellent barrier and carbonization property of the hybrid coating.

Correlation of Montmorillonite Sheet Thickness and Flame Retardant Behavior of a Chitosan⁻Montmorillonite Nanosheet Membrane Assembled on Flexible Polyurethane Foam

Polymer⁻clay membranes constructed via the layer-by-layer (LbL) assembly, with a nanobrick wall structure, are known to exhibit high flame retardancy. In this work, chitosan⁻montmorillonite nanosheet (CH⁻MMTNS) membranes with different thickness of MMTNS were constructed to suppress the flammability of flexible polyurethane (FPU) foam. It was found that a thinner MMTNS membrane was more efficient in terms of reducing the flammability of the FPU foam. This was because such MMTNS membrane could deposit cheek by jowl and form a dense CH⁻MMTNS membrane on the foam surface, thus greatly limiting the translation of heat, oxygen, and volatile gases. In contrast, a thicker MMTNS constructed a fragmentary CH⁻MMTNS membrane on the coated foam surface, due to its greater gravity and weaker electrostatic attraction of chitosan; thus, the flame retardancy of a thick MMTNS membrane was lower. Moreover, the finding of different deposition behaviors of MMTNS membranes with different thickness may suggest improvements for the application of clay with the LbL assembly technology.

Tuning the Nanoscale Properties of Phosphorylated Cellulose Nanofibril-Based Thin Films To Achieve Highly Fire-Protecting Coatings for Flammable Solid Materials

Ultrathin nanocomposite films were prepared by combining cellulose nanofibrils (CNFs) prepared from phosphorylated pulp fibers (P-CNF) with montmorillonite (MMT), sepiolite (Sep) clay, or sodium hexametaphosphate (SHMP). The flame-retardant and heat-protective capability of the prepared films as casings for a polyethylene (PE) film was investigated. Heating the coated PE in air revealed that the polymer film was thoroughly preserved up to at least 300 °C. The P-CNF/MMT coatings were also able to completely prevent the ignition of the PE film during cone calorimetry, but neither the P-CNF/Sep nor the P-CNF/SHMP coating could entirely prevent PE ignition. This was explained by the results from combined thermogravimetry Fourier transform infrared spectroscopy, which showed that the P-CNF/MMT film was able to delay the release of PE decomposition volatiles and shift its thermal degradation to a higher temperature. The superior flame-retardant performance of the P-CNF/MMT films is mainly attributed to the unique compositional and structural features of the film, where P-CNF is responsible for increasing the char formation, whereas the MMT platelets create excellent barrier and thermal shielding properties by forming inorganic lamellae within the P-CNF matrix. These films showed a tensile strength of 304 MPa and a Young's modulus of 15 GPa with 10 wt % clay so that this composite film was mechanically stronger than the previously prepared CNF/clay nanopapers containing the same amount of clay.

Near-Infrared Light and Solar Light Activated Self-Healing Epoxy Coating having Enhanced Properties Using MXene Flakes as Multifunctional Fillers

Two issues are required to be solved to bring intrinsically self-healing polymer coatings into real applications: remote activation and satisfied practical properties. Here, we used MXene, a newly reported two-dimensional material, to provide an epoxy coating with light-induced self-healing capabilities and we worked to enhance the properties of that coating. The self-healing coatings had a reversible crosslinking network based on the Diels-Alder reaction among maleimide groups from bis(4-maleimidopheny)methane and dangling furan groups in oligomers that were prepared through the condensation polymerization of diglycidylether of bisphenol A and furfurylamine. The results showed that the delaminated MXene flakes were small in size, around 900 nm, and dispersed well in self-healing coatings. The MXene flakes of only 2.80 wt % improved greatly the pencil hardness of the coating hardness from HB to 5H and the polarization resistance from 4.3 to 428.3 MΩ cm-2. The self-healing behavior, however, was retarded by MXene flakes. Leveling agent acted a key part here to facilitate the gap closure driven by reverse plasticity to compensate for the limitation of macromolecular mobility resulting from the MXene flakes. The self-healing of coatings was achieved in 30 s by thermal treatment at 150 °C. The efficient self-healing was also demonstrated based on the recovery of the anti-corrosion capability. MXene flakes also played an evident photothermal role in generating heat via irradiation of near-infrared light at 808 nm and focused sunlight. The healing can be quickly obtained in 10 s under irradiation of near-infrared light at 808 nm having a power density of 6.28 W cm-2 or in 10 min under irradiation of focused sunlight having a power density of 4.0 W cm-2.

Biobased polyelectrolyte multilayer-coated hollow mesoporous silica as a green flame retardant for epoxy resin

Here, we describe a multifunctional biobased polyelectrolyte multilayer-coated hollow mesoporous silica (HM-SiO₂@CS@PCL) as a green flame retardant through layer-by-layer assembly using hollow mesoporous silica (HM-SiO₂), chitosan (CS) and phosphorylated cellulose (PCL). The electrostatic interactions deposited the CS/PCL coating on the surface of HM-SiO₂. Subsequently, this multifunctional flame retardant was used to enhance thermal properties and flame retardancy of epoxy resin. The addition of HM-SiO₂@CS@PCL to the epoxy resin thermally destabilized the epoxy resin composite, but generated a higher char yield. Furthermore, HM-SiO₂ played a critical role and generated synergies with CS and PCL to improve fire safety of the epoxy resin due to the multiple flame retardancy elements (P, N and Si). This multi-element, synergistic, flame-retardant system resulted in a remarkable reduction (51%) of peak heat release rate and a considerable removal of flammable decomposed products. Additionally, the incorporation of HM-SiO₂@CS@PCL can sustainably recycle the epoxy resin into high value-added hollow carbon spheres during combustion. Therefore, the HM-SiO₂@CS@PCL system provides a practical possibility for preparing recyclable polymer materials with multi-functions and high performances.

All-Inorganic Intumescent Nanocoating Containing Montmorillonite Nanoplatelets in Ammonium Polyphosphate Matrix Capable of Preventing Cotton Ignition

In the present manuscript a new concept of completely inorganic intumescent flame retardant nanocoating comprised of sodium montmorillonite nanoplatelets embedded in an ammonium polyphosphate matrix has been investigated using cotton as model substrate. The coating, deposited by multistep adsorption from diluted water-based suspensions/solutions, homogenously cover each cotton fibers with average thicknesses below 50 nm and add-on up to 5% in weight. Combustion characterization evidences the interesting properties: indeed, the so-treated fabrics reached self-extinguishing during horizontal flame spread tests. Furthermore, when the coating add-on reaches 5%, no ignition has been observed during cone calorimetry tests under 35 kW/m² heat flux. Residue analyses pointed out the formation of an expanded all-inorganic coating capable of greatly improving char formation by exerting barrier function towards volatile release and heat transfer.

Water-Based Melanin Multilayer Thin Films with Broadband UV Absorption

Natural melanin is difficult to process due to its poor solubility and poorly understood structure. Synthetic melanin has been produced more recently, which is dispersible in mildly alkaline water and has many of the same properties of natural melanin. In this study, thin films of synthetic melanin and poly(allylamine hydrochloride) were deposited layer-by-layer from dilute aqueous solutions in ambient conditions. This is likely the first time melanin has been deposited from water to produce a functional nanocoating. These films display broadband UV light absorption, absorbing over 63% of incident light that is most damaging to human eyes with a thickness of 108 nm. In an effort to demonstrate the utility of these melanin-based nanocoatings, a 30 bilayer film is shown to increase the useful life of a conductive poly(3,4-ethylenedioxythiophene)/poly(styrenesulfonate) (PEDOT/PSS) film by 550%. This novel method of depositing melanin should open the door to a variety of useful applications.

Formation of layer-by-layer assembled titanate nanotubes filled coating on flexible polyurethane foam with improved flame retardant and smoke suppression properties

A fire blocking coating made from chitosan, titanate nanotubes and alginate was deposited on a flexible polyurethane (FPU) foam surface by a layer-by-layer assembly technique in an effort to reduce its flammability. First, titanate nanotubes were prepared by a hydrothermal method. And then the coating growth was carried out by alternately submerging FPU foams into chitosan solution, titanate nanotubes suspension and alginate solution. The mass gain of coating on the surface of FPU foams showed dependency on the concentration of titanate nanotubes suspension and the trilayers's number. Scanning electron microscopy indicated that titanate nanotubes were distributed well on the entire surface of FPU foam and showed a randomly oriented and entangled network structure. The cone calorimeter result indicated that the coated FPU foams showed reduction in the peak heat release rate (peak HRR), peak smoke production rate (peak SPR), total smoke release (TSR) and peak carbon monoxide (CO) production compared with those of the control FPU foam. Especially for the FPU foam with only 5.65 wt % mass gain, great reduction in peak HRR (70.2%), peak SPR (62.8%), TSR (40.9%) and peak CO production (63.5%) could be observed. Such a significant improvement in flame retardancy and the smoke suppression property for FPU foam could be attributed to the protective effect of titanate nanotubes network structure formed, including insulating barrier effect and adsorption effect.

A novel and effective method to fabricate flame retardant and smoke suppressed flexible polyurethane foam

In the present work, magnesium hydroxide were successfully deposited on the surface of flexible polyurethane foam to suppress its flammability and smoke production.

Inorganic nanoparticle thin film that suppresses flammability of polyurethane with only a single electrostatically-assembled bilayer

In an effort to reduce the flammability of polyurethane foam, a thin film of renewable inorganic nanoparticles (i.e., anionic vermiculite [VMT] and cationic boehmite [BMT]) was deposited on polyurethane foam via layer-by-layer (LbL) assembly. One, two, and three bilayers (BL) of BMT-VMT resulted in foam with retained shape after being exposed to a butane flame for 10 s, while uncoated foam was completely consumed. Cone calorimetry confirmed that the coated foam exhibited a 55% reduction in peak heat release rate with only a single bilayer deposited. Moreover, this protective nanocoating reduced total smoke release by 50% relative to untreated foam. This study revealed that 1 BL, adding just 4.5 wt % to PU foam, is an effective and conformal flame retardant coating. These results demonstrate one of the most efficient and renewable nanocoatings prepared using LbL assembly, taking this technology another step closer to commercial viability.

Synthesis of mesoporous silica@Co-Al layered double hydroxide spheres: layer-by-layer method and their effects on the flame retardancy of epoxy resins

Hierarchical mesoporous silica@Co-Al layered double hydroxide (m-SiO2@Co-Al LDH) spheres were prepared through a layer-by-layer assembly process, in order to integrate their excellent physical and chemical functionalities. TEM results depicted that, due to the electrostatic potential difference between m-SiO2 and Co-Al LDH, the synthetic m-SiO2@Co-Al LDH hybrids exhibited that m-SiO2 spheres were packaged by the Co-Al LDH nanosheets. Subsequently, the m-SiO2@Co-Al LDH spheres were incorporated into epoxy resin (EP) to prepare specimens for investigation of their flame-retardant performance. Cone results indicated that m-SiO2@Co-Al LDH incorporated obviously improved fire retardant of EP. A plausible mechanism of fire retardant was hypothesized based on the analyses of thermal conductivity, char residues, and pyrolysis fragments. Labyrinth effect of m-SiO2 and formation of graphitized carbon char catalyzed by Co-Al LDH play pivotal roles in the flame retardance enhancement.

High gas barrier imparted by similarly charged multilayers in nanobrick wall thin films

Super oxygen barrier trilayer thin films have been deposited using two successive anionic layers of clay and polymer following every cationic polymer layer.