High performance nano-zinc amino-tris-(methylenephosphonate) in rigid polyurethane foam with improved mechanical strength, thermal stability and flame retardancy

Elaboration of Thermally Performing Polyurethane Foams, Based on Biopolyols, with Thermal Insulating Applications

In this work, biobased rigid polyurethane foams (PUFs) were developed with the aim of achieving thermal and fireproofing properties that can compete with those of the commercially available products. First, the synthesis of a biopolyol from a wood residue by means of a scaled-up process with suitable yield and reaction conditions was carried out. This biopolyol was able to substitute completely the synthetic polyols that are typically employed within a polyurethane formulation. Different formulations were developed to assess the effect of two flame retardants, namely, polyhedral oligomeric silsesquioxane (POSS) and amino polyphosphate (APP), in terms of their thermal properties and degradation and their fireproofing mechanism. The structure and the thermal degradation of the different formulations was evaluated via Fourier Transformed Infrared Spectroscopy (FTIR) and thermogravimetric analysis (TGA). Likewise, the performance of the different PUF formulations was studied and compared to that of an industrial PUF. From these results, it can be highlighted that the addition of the flame retardants into the formulation showed an improvement in the results of the UL-94 vertical burning test and the LOI. Moreover, the fireproofing performance of the biobased formulations was comparable to that of the industrial one. In addition to that, it can be remarked that the biobased formulations displayed an excellent performance as thermal insulators (0.02371-0.02149 W·m-1·K-1), which was even slightly higher than that of the industrial one.

Study on flame retardancy and thermal stability of rigid polyurethane foams modified by amino trimethylphosphonate cobalt and expandable graphite

Amino trimethylphosphonate cobalt (Co2+-ATMP) flame retardant was prepared by ion exchange method, and rigid polyurethane foam (RPUF) modified by Co2+-ATMP and expandable graphite (EG) was prepared by one-pot and free-rise method. The flame retardancy, thermal stability and smoke toxicity of modified RPUF were studied by limiting oxygen index (LOI), cone calorimeter (Cone), thermogravimetric analysis (TG) and smoke toxicity characterization. The results showed that the flame retardancy, thermal stability and smoke toxicity of RPUF modified by Co2+-ATMP and EG are significantly improved. When the ratio of Co2+-ATMP to EG is 1:5, the LOI value is the highest, and the toxicity of flue gas was the lowest. The peak heat release rate (PHRR) and total heat release rate (THR) were both the lowest, 138 kW/m2 and 15.9 MJ/m2, respectively. Compared with RPUF-0, it decreased by 39.2% and 16.8% respectively. The research results can provide reference for the subsequent flame retardant modification of RPUF.

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.

Investigating Physio-Thermo-Mechanical Properties of Polyurethane and Thermoplastics Nanocomposite in Various Applications

The effect of the soft and hard polyurethane (PU) segments caused by the hydrogen link in phase-separation kinetics was studied to investigate the morphological annealing of PU and thermoplastic polyurethane (TPU). The significance of the segmented PUs is to achieve enough stability for further applications in biomedical and environmental fields. In addition, other research focuses on widening the plastic features and adjusting the PU-polyimide ratio to create elastomer of the poly(urethane-imide). Regarding TPU- and PU-nanocomposite, numerous studies investigated the incorporation of inorganic nanofillers such as carbon or clay to incorporating TPU-nanocomposite in several applications. Additionally, the complete exfoliation was observed up to 5% and 3% of TPU-clay modified with 12 amino lauric acid and benzidine, respectively. PU-nanocomposite of 5 wt.% Cloisite®30B showed an increase in modulus and tensile strength by 110% and 160%, respectively. However, the nanocomposite PU-0.5 wt.% Carbone Nanotubes (CNTs) show an increase in the tensile modulus by 30% to 90% for blown and flat films, respectively. Coating PU influences stress-strain behavior because of the interaction between the soft segment and physical crosslinkers. The thermophysical properties of the TPU matrix have shown two glass transition temperatures (Tg's) corresponding to the soft and the hard segment. Adding a small amount of tethered clay shifts Tg for both segments by 44 °C and 13 °C, respectively, while adding clay from 1 to 5 wt.% results in increasing the thermal stability of TPU composite from 12 to 34 °C, respectively. The differential scanning calorimetry (DSC) was used to investigate the phase structure of PU dispersion, showing an increase in thermal stability, solubility, and flexibility. Regarding the electrical properties, the maximum piezoresistivity (10 S/m) of 7.4 wt.% MWCNT was enhanced by 92.92%. The chemical structure of the PU-CNT composite has shown a degree of agglomeration under disruption of the sp2 carbon structure. However, with extended graphene loading to 5.7 wt.%, piezoresistivity could hit 10-1 S/m, less than 100 times that of PU. In addition to electrical properties, the acoustic behavior of MWCNT (0.35 wt.%)/SiO2 (0.2 wt.%)/PU has shown sound absorption of 80 dB compared to the PU foam sample. Other nanofillers, such as SiO2, TiO2, ZnO, Al2O3, were studied showing an improvement in the thermal stability of the polymer and enhancing scratch and abrasion resistance.

Bioinspired, Highly Adhesive, Nanostructured Polymeric Coatings for Superhydrophobic Fire-Extinguishing Thermal Insulation Foam

Lightweight polymeric foam is highly attractive as thermal insulation materials for energy-saving buildings but is plagued by its inherent flammability. Fire-retardant coatings are suggested as an effective means to solve this problem. However, most of the existing fire-retardant coatings suffer from poor interfacial adhesion to polymeric foam during use. In nature, snails and tree frogs exhibit strong adhesion to a variety of surfaces by interfacial hydrogen-bonding and mechanical interlocking, respectively. Inspired by their adhesion mechanisms, we herein rationally design fire-retardant polymeric coatings with phase-separated micro/nanostructures via a facile radical copolymerization of hydroxyethyl acrylate (HEA) and sodium vinylsulfonate (VS). The resultant waterborne poly(VS-co-HEA) copolymers exhibit strong interfacial adhesion to rigid polyurethane (PU) foam and other substrates, better than most of the current adhesives because of the combination of interfacial hydrogen-bonding and mechanical interlocking. Besides a superhydrophobic feature, the poly(VS-co-HEA)-coated PU foam can self-extinguish a flame, exhibiting a desired V-0 rating during vertical burning and low heat and smoke release due to its high charring capability, which is superior to its previous counterparts. Moreover, the foam thermal insulation is well-preserved and agrees well with theoretical calculations. This work offers a facile biomimetic strategy for creating advanced adhesive fire-retardant polymeric coatings for many flammable substrates.

Effects of Various Types of Expandable Graphite and Blackcurrant Pomace on the Properties of Viscoelastic Polyurethane Foams

We investigated the effect of the type and amount of expandable graphite (EG) and blackcurrant pomace (BCP) on the flammability, thermal stability, mechanical properties, physical, and chemical structure of viscoelastic polyurethane foams (VEF). For this purpose, the polyurethane foams containing EG, BCP, and EG with BCP were obtained. The content of EG varied in the range of 3-15 per hundred polyols (php), while the BCP content was 30 php. Based on the obtained results, it was found that the additional introduction of BCPs into EG-containing composites allows for an additive effect in improving the functional properties of viscoelastic polyurethane foams. As a result, the composite containing 30 php of BCP and 15 php of EG with the largest particle size and expanded volume shows the largest change in the studied parameters (hardness (H) = 2.65 kPa (+16.2%), limiting oxygen index (LOI) = 26% (+44.4%), and peak heat release rate (pHRR) = 15.5 kW/m2 (-87.4%)). In addition, this composite was characterized by the highest char yield (m600 = 17.9% (+44.1%)). In turn, the change in mechanical properties is related to a change in the physical and chemical structure of the foams as indicated by scanning electron microscopy (SEM) and Fourier transform infrared spectroscopy (FTIR) analysis.

Effect of tris(1-chloro-2-propyl)phosphate in combination with aluminum hypophosphite and melamine polyphosphate on flame retardancy and thermal decomposition of rigid polyurethane foams

RPUF with tris(1-chloro-2-propyl)phosphate (TCPP), melamine polyphosphate (MPP) and aluminum hypophosphite (AHP) alone, as well as their binary and ternary blends, were prepared via a one-step process. The effect of TCPP in combination with AHP and MPP on flame retardancy and thermal decomposition in the RPUF has been investigated. The results show that adding TCPP, MPP and AHP into RPUF simultaneously can significantly ensure the uniform cell structure, enhance the compressive strength, thermal stability and fire resistance of RPUF, decrease the thermal conductivity, the release of toxic HCN at high temperature. TGA results indicate that partial substitution of TCPP with MPP and AHP could improve the char residue. When the content of TCPP is 10 wt%, the optimal ratio of MPP and DPER was 1/2, the TCPP10/MPP3.3/AHP6.7/RPUF sample reached a V1 rating in vertical UL-94 test with a limiting oxygen index of 27.4%. The compressive strength and specific compressive strength (compressive strength/density) for TCPP10/MPP3.3/AHP6.7/RPUF sample increased about 82.6% and 44.3% compared to that of pure RPUF, respectively. The cone calorimeter test results showed that adding EG, MPP and AHP into RPUF simultaneously can significantly decrease the heat release rate (HRR), total heat release (THR) and smoke emission behavior of RPUF sample. Based on these facts, a potential flame-retardant mechanism was proposed.

Mesoporous silica via self-assembly of nano zinc amino-tris-(methylenephosphonate) exhibiting reduced fire hazards and improved impact toughness in epoxy resin

Mesoporous silica@nano-zinc amino-tris-(methylenephosphonate) (m-SiO₂@Zn-AMP) spheres were synthesized via a self-assembly process to integrate the outstanding flame retardancy, thermal stability, and mechanical properties of these materials. The results indicated that nano Zn-AMP particles were successfully deposited on the surface of m-SiO₂ through electrostatic interactions. The prepared m-SiO₂@Zn-AMP was utilized to improve the flame retardancy, smoke suppression, and mechanical properties of epoxy resin (EP). The storage modulus, impact, and tensile strengths of the EP with 1% m-SiO₂@Zn-AMP (sample EP/1m-SiO₂@Zn-AMP) were increased by 29.9, 50.0, and 23.5 %, respectively, relative to the values for untreated EP. The presence of multiple flame retardant elements (i.e. Si, P, N, and Zn) in the mesoporous spheres led to the formation of high yields of compact char residues and the release of inert substance during combustion, for high flame retardancy and efficient smoke suppression in the condensed and gaseous phase. The EP/5m-SiO₂@Zn-AMP sample achieved a V0 rating in a vertical UL-94 test. Compared to untreated EP, the amount of total smoke released and the peak CO production rate of EP/5m-SiO₂@Zn-AMP were reduced by 53.1 and 61.5 %, respectively. Additionally, the total heat release and peak heat release rate of EP/5m-SiO₂@Zn-AMP were decreased by 45.2 and 57.8 %, respectively.

Rigid polyurethane/expanded vermiculite/ melamine phenylphosphate composite foams with good flame retardant and mechanical properties

Expanded vermiculite (EV) was introduced into rigid polyurethane (RPU) foam. The incorporation of 10 wt% EV into RPU foam increases the compressive strength and the flexural strength by 82% and by 115%, respectively compared with untreated RPU foam. The LOI of RPU foam containing 20 wt% EV is only 19.5%. To further improve the flame retardancy of RPU/EV composite foam, melamine phenylphosphate (MPP) was synthesized and introduced into the RPU/EV composite foam. The RPU/EV composite foam with 15% MPP (sample RPU/EV/MPP15) has a LOI of 27.5% and a V0 rating in the vertical UL-94 test. The PHRR and THR of sample RPU/EV/MPP15 decrease by 39% and 24%, respectively, compared with the ones of untreated RPU/EV composite foam. The compressive strength and flexural strength of RPU/EV/MPP composite foam gradually decrease with the increase in the amount of MPP. TGA results indicated that the addition of MPP further increase the residue char of the RPU/EV composite foam.

Recent Trends of Foaming in Polymer Processing: A Review

Polymer foams have low density, good heat insulation, good sound insulation effects, high specific strength, and high corrosion resistance, and are widely used in civil and industrial applications. In this paper, the classification of polymer foams, principles of the foaming process, types of blowing agents, and raw materials of polymer foams are reviewed. The research progress of various foaming methods and the current problems and possible solutions are discussed in detail.