Layer-by-layer assembly of efficient flame retardant coatings based on high aspect ratio graphene oxide and chitosan capable of preventing ignition of PU foam

Construction of sustainable and highly efficient fire-protective nanocoatings based on polydopamine and phosphorylated cellulose for flexible polyurethane foam

Layer-by-layer (LBL) self-assembly is an effective strategy for constructing fire-resistant coatings on flexible polyurethane foam (FPUF), while the efficiency of fire-resistant coatings remains limited. Therefore, this study proposes an in situ flame retardancy modification combined with LBL self-assembly technology to enhance the efficiency of flame retardant coatings for FPUF. Initially, polydopamine (PDA) and polyethyleneimine (PEI) were employed to modify the FPUF skeleton, thereby augmenting the adhesion on the surface of the skeleton network. Then, the self-assembly of MXene and phosphorylated cellulose nanofibers (PCNFs) via the LBL technique on the foam skeleton network formed a novel, sustainable, and efficient flame retardant system. The final fire-protective coatings comprising PDA/PEI and MXenes/PCNF effectively prevented the collapse of the foam structure and suppressed the melt dripping of the FPUF during combustion. The peak heat release rate, the peak CO production rate and peak CO2 production rate were reduced by 68.6 %, 61.1 %, and 68.4 % only by applying a 10-bilayer coating. In addition, the smoke release rate and total smoke production were reduced by 83.3 % and 57.7 %, respectively. This work offers a surface modification approach for constructing highly efficient flame retardant coatings for flammable polymeric materials.

Flame retardant and superoleophilic polydopamine/chitosan-graft (g)-octanal coated polyurethane foam for separation oil/water mixtures

The discharge of crude petroleum oils and their derivatives poses serious environmental challenges, which can be mitigated through oil/water separation. In this study, polyurethane (PU)/polydopamine (PDA)/chitosan-graft (g)-octanal foam was prepared by immersing of PU foam in PDA and chitosan-g-octanal solutions. The fabricated PU foam exhibited thermal stability, flame retardancy, and hydrophobicity/superoleophilicity. The coated PU foam can selectively absorb heavy and light oils from dynamic and static oil/water mixtures. The maximum sorption capacity for olive oil was found to be as high as 41.48 g/g. PU/PDA/chitosan-g-octanal foam also demonstrated excellent flame retardancy and the ability to quickly extinguish fire, as confirmed by the limiting oxygen index (LOI) test.

Layer-by-Layer-Coated Cellulose Fibers Enable the Production of Porous, Flame-Retardant, and Lightweight Materials

New sustainable materials produced by green processing routes are required in order to meet the concepts of circular economy. The replacement of insulating materials comprising flammable synthetic polymers by bio-based materials represents a potential opportunity to achieve this task. In this paper, low-density and flame-retardant (FR) porous fiber networks are prepared by assembling Layer-by-Layer (LbL)-functionalized cellulose fibers by means of freeze-drying. The LbL coating, encompassing chitosan and sodium hexametaphosphate, enables the formation of a self-sustained porous structure by enhancing fiber-fiber interactions during the freeze-drying process. Fiber networks prepared from 3 Bi-Layer (BL)-coated fibers contain 80% wt of cellulose and can easily self-extinguish the flame during flammability tests in vertical configuration while displaying extremely low combustion rates in forced combustion tests. Smoke release is 1 order of magnitude lower than that of commercially available polyurethane foams. Such high FR efficiency is ascribed to the homogeneity of the deposited assembly, which produces a protective exoskeleton at the air/cellulose interface. The results reported in this paper represent an excellent opportunity for the development of fire-safe materials, encompassing natural components where sustainability and performance are maximized.

Fireproof Nanocomposite Polyurethane Foams: A Review

First introduced in 1954, polyurethane foams rapidly became popular because of light weight, high chemical stability, and outstanding sound and thermal insulation properties. Currently, polyurethane foam is widely applied in industrial and household products. Despite tremendous progress in the development of various formulations of versatile foams, their use is hindered due to high flammability. Fire retardant additives can be introduced into polyurethane foams to enhance their fireproof properties. Nanoscale materials employed as fire-retardant components of polyurethane foams have the potential to overcome this problem. Here, we review the recent (last 5 years) progress that has been made in polyurethane foam modification using nanomaterials to enhance its flame retardance. Different groups of nanomaterials and approaches for incorporating them into foam structures are covered. Special attention is given to the synergetic effects of nanomaterials with other flame-retardant additives.

Comprehensive Review of Recent Research Advances on Flame-Retardant Coatings for Building Materials: Chemical Ingredients, Micromorphology, and Processing Techniques

Developing fire-retardant building materials is vital in reducing fire loss. The design and preparation of novel fire-retardant coatings merely require the adhesion of flame retardants with high fire-retardant characteristics on the surface, which is significantly more economical than adding excessive amounts of flame retardants into bulk building materials. Meanwhile, fire-retardant coating has excellent performance because it can block the self-sustaining mechanisms of heat and mass transfer over combustion interfaces. In recent years, research of fire-retardant coatings for building materials has been subject to rapid development, and a variety of novel environmentally benign fire-retardant coatings have been reported. Nonetheless, as the surface characteristics of various flammable building materials are contrastively different, selecting chemical ingredients and controlling the physical morphology of fire-retardant coatings for specific building materials is rather complicated. Thus, it is urgent to review the ideas and preparation methods for new fire-retardant coatings. This paper summarizes the latest research progress of fire-retardant building materials, focusing on the compositions and performances of fire-retardant coatings, as well as the principles of their bottom-up design and preparation methods on the surface of building materials.

Environmental, Health, and Legislation Considerations for Rational Design of Nonreactive Flame-Retardant Additives for Polymeric Materials: Future Perspectives

Increasing polymer usage has demanded functional additives that decrease fire hazards for end users. While traditional flame-retardant (FR) additives, such as halogenated, phosphorus, and metal hydroxides, greatly reduce flammability and associated fire hazards, research has continually exposed a litany of health and environmental safety concerns. This perspective aims to identify the key components of a successful FR additive and address material, environmental, and health concerns of existing additives. Legislation surrounding FRs and persistent organic pollutants is also discussed to highlight political perception that has resulted in the increased chemical regulations and subsequent banning of FR additives. Finally, future directions of this field regarding nonreactive additives, focusing on the use of bioinspired materials and transition metal chemistries to produce alternatives for polymers with efficacies surpassing traditional additives are presented.

Polyelectrolyte-Assisted Dispersions of Reduced Graphite Oxide Nanoplates in Water and Their Gas-Barrier Application

Dispersion of graphene and related materials in water is needed to enable sustainable processing of these 2D materials. In this work, we demonstrate the capability of branched polyethylenimine (BPEI) and polyacrylic acid (PAA) to stabilize reduced graphite oxide (rGO) dispersions in water. Atomic force microscopy colloidal probe measurements were carried out to investigate the interaction mechanisms between rGO and the polyelectrolytes (PEs). Our results show that for positive PEs, the interaction appears electrostatic, originating from the weak negative charge of graphene in water. For negative PEs, however, van der Waals forces may result in the formation of a PE shell on rGO. The PE-stabilized rGO dispersions were then used for the preparation of coatings to enhance gas barrier properties of polyethylene terephthalate films using the layer-by-layer self-assembly. Ten bilayers of rGO_BPEI/rGO_PAA resulted in coatings with excellent barrier properties as demonstrated by oxygen transmission rates below detection limits [<0.005 cm³/(m² day atm)]. The observed excellent performance is ascribed to both the high density of the deposited coating and its efficient stratification. These results can enable the design of highly efficient gas barrier solutions for demanding applications, including oxygen-sensitive pharmaceutical products or flexible electronic devices.

Nanocarbon-Based Flame Retardant Polymer Nanocomposites

In recent years, nanocarbon materials have attracted the interest of researchers due to their excellent properties. Nanocarbon-based flame retardant polymer composites have enhanced thermal stability and mechanical properties compared with traditional flame retardant composites. In this article, the unique structural features of nanocarbon-based materials and their use in flame retardant polymeric materials are initially introduced. Afterwards, the flame retardant mechanism of nanocarbon materials is described. The main discussions include material components such as graphene, carbon nanotubes, fullerene (in preparing resins), elastomers, plastics, foams, fabrics, and film-matrix materials. Furthermore, the flame retardant properties of carbon nanomaterials and their modified products are summarized. Carbon nanomaterials not only play the role of a flame retardant in composites, but also play an important role in many aspects such as mechanical reinforcement. Finally, the opportunities and challenges for future development of carbon nanomaterials in flame-retardant polymeric materials are briefly discussed.

Chitosan-based smart hybrid materials: a physico-chemical perspective

Chitosan is one of the most studied cationic polysaccharides. Due to its unique characteristics of being water soluble, biocompatible, biodegradable, and non-toxic, this macromolecule is highly attractive for a broad range of applications. In addition, its complex behavior and the number of ways it interacts with different components in a system result in an astonishing variety of chitosan-based materials. Herein, we present recent advances in the field of chitosan-based materials from a physico-chemical perspective, with focus on aqueous mixtures with oppositely charged colloids, chitosan-based thin films, and nanocomposite systems. In this review, we focus our attention on the physico-chemical properties of chitosan-based materials, including solubility, mechanical resistance, barrier properties, and thermal behaviour, and provide a link to the chemical peculiarities of chitosan, such as its intrinsic low solubility, high rigidity, large charge separation, and strong tendency to form intra- and inter-molecular hydrogen bonds.

The use of model cellulose gel beads to clarify flame-retardant characteristics of layer-by-layer nanocoatings

Layer-by-Layer (LbL) assembled nanocoatings are exploited to impart flame-retardant properties to cellulosic substrates. A model cellulose material can make it possible to investigate an optimal bilayer (BL) range for the deposition of coating while elucidating the main flame-retardant action thus allowing for an efficient design of optimized LbL formulations. Model cellulose gel beads were prepared by dissolving cellulose-rich fibers followed by precipitation. The beads were LbL-treated with chitosan (CH) and sodium hexametaphosphate (SHMP). The char forming properties were studied using thermal gravimetric analysis. The coating increased the char yield in nitrogen to up to 29 % and showed a distinct pattern of micro intumescent behavior upon heating. An optimal range of 10-20 BL is observed. The well-defined model cellulose gel beads hence introduce a new scientific route both to clarify the fundamental effects of different film components and to optimize the composition of the films.

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.

Fire-Safe Polymer Composites: Flame-Retardant Effect of Nanofillers

Currently, polymers are competing with metals and ceramics to realize various material characteristics, including mechanical and electrical properties. However, most polymers consist of organic matter, making them vulnerable to flames and high-temperature conditions. In addition, the combustion of polymers consisting of different types of organic matter results in various gaseous hazards. Therefore, to minimize the fire damage, there has been a significant demand for developing polymers that are fire resistant or flame retardant. From this viewpoint, it is crucial to design and synthesize thermally stable polymers that are less likely to decompose into combustible gaseous species under high-temperature conditions. Flame retardants can also be introduced to further reinforce the fire performance of polymers. In this review, the combustion process of organic matter, types of flame retardants, and common flammability testing methods are reviewed. Furthermore, the latest research trends in the use of versatile nanofillers to enhance the fire performance of polymeric materials are discussed with an emphasis on their underlying action, advantages, and disadvantages.

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.

Environmentally Benign and Self-Extinguishing Multilayer Nanocoating for Protection of Flammable Foam

Most current flame-retardant nanocoatings for flexible polyurethane foam (PUF) consist of passive barriers, such as clay, graphene oxide, or metal hydroxide. In an effort to develop a polymeric and environmentally benign nanocoating for PUF, positively charged chitosan (CH) and anionic sodium hexametaphosphate (PSP) were deposited using layer-by-layer (LbL) assembly. Only six bilayers of CH/PSP film can withstand flame penetration during exposure to a butane torch (∼1400 °C) for 10 s and stop flame spread on the foam. Additionally, cone calorimetry reveals that the fire growth rate, peak heat release rate, and maximum average rate of heat emission are reduced by 55, 43, and 38%, respectively, compared with uncoated foam. This multilayer thin film quickly dehydrates to form an intumescent charred exoskeleton on the surface of the open-celled structure of polyurethane, inhibiting heat transfer and completely eliminating melt dripping. This entirely polymeric nanocoating provides a safe and effective alternative for reducing the fire hazard of polyurethane foam that is widely used for cushioning and insulation.

Polydopamine-Bridged Synthesis of Ternary h-BN@PDA@TiO2 as Nanoenhancers for Thermal Conductivity and Flame Retardant of Polyvinyl Alcohol

In this study, h-BN@PDA@TiO₂ hybrid nanoparticles were prepared and used as functional fillers to prepare PVA nanocomposites, and the effects of hybrid particles on PVA thermal conductivity and flame retardant properties were studied. The results showed that hybrid particles could significantly improve the thermal conductivity and flame retardant performance of PVA composites, and effectively inhibit the release of toxic gases such as combustible pyrolysis products and CO, which enhanced the fire safety of PVA composites. When the addition amount of hybrid particles is 5 wt%, the thermal conductivity of PVA composites is 239.1% higher than that of the pure PVA and the corresponding temperature of PVA composites with a mass loss of 5 wt% was 16.2°C higher than that of the pure PVA. This is due to the barrier effect of h-BN and the protective effect of dense carbon layer catalyzed by TiO₂.

Flame-Retardant Systems Based on Chitosan and Its Derivatives: State of the Art and Perspectives

During the last decade, the utilization of chitin, and in par0ticular its deacetylated form, i.e., chitosan, for flame retardant purposes, has represented quite a novel and interesting application, very far from the established uses of this bio-sourced material. In this context, chitosan is a carbon source that can be successfully exploited, often in combination with intumescent products, in order to provide different polymer systems (namely, bulky materials, fabrics and foams) with high flame retardant (FR) features. Besides, this specific use of chitosan in flame retardance is well suited to a green and sustainable approach. This review aims to summarize the recent advances concerning the utilization of chitosan as a key component in the design of efficient flame retardant systems for different polymeric materials.

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.

Mica-Based Multilayer Nanocoating as a Highly Effective Flame Retardant and Smoke Suppressant

Highly flammable polyurethane foam (PUF) remains a key risk factor associated with bedding and upholstered furniture, contributing to the yearly destruction of property and loss of lives. In an attempt to tackle this issue and develop a more benign flame retardant for PUF, a mica-based nanocomposite was deposited using layer-by-layer assembly. Chitosan (CH) and poly(acrylic acid) (PAA) were used to stabilize high-aspect-ratio mica. Foam treated with eight bilayers of CH- and PAA-stabilized mica preserves the porous foam structure, prevents melt dripping, and self-extinguishes during a 10 s torch test, while uncoated foam is completely consumed. When exposed to 35 kW/m² heat flux during cone calorimetry, the peak heat release rate is reduced by 54% and less-volatile molecules are released during combustion, resulting in a 76% reduction in the total smoke release. This multilayer coating serves as an environmentally benign template for flame-retarding PUF and various other three-dimensional substrates.

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.

A green self-assembled organic supermolecule as an effective flame retardant for epoxy resin

In this study, a green organic supermolecule as an effective flame retardant for epoxy resin was prepared.

Physico-Mechanical and Thermodynamic Properties of Mycelium-Based Biocomposites: A Review

Reducing the use of non-renewable resources is a key strategy of a circular economy. Mycelium-based foams and sandwich composites are an emerging category of biocomposites relying on the valorization of lignocellulosic wastes and the natural growth of the living fungal organism. While growing, the fungus cements the substrate, which is partially replaced by the tenacious biomass of the fungus itself. The final product can be shaped to produce insulating panels, packaging materials, bricks or new-design objects. Only a few pioneer companies in the world retain a significant know-how, as well as the ability to provide the material characterization. Moreover, several technical details are not revealed due to industrial secrecy. According to the available literature, mycelium-based biocomposites show low density and good insulation properties, both related to acoustic and thermal aspects. Mechanical properties are apparently inferior in comparison to expanded polystyrene (EPS), which is the major synthetic competitor. Nevertheless, mycelium-based composites can display an enormous variability on the basis of: fungal species and strain; substrate composition and structure; and incubation conditions. The aim of the present review is to summarize technical aspects and properties of mycelium-based biocomposites focusing on both actual applications and future perspectives.