Fabrication of flexible polyurethane/phosphorus interpenetrating polymer network (IPN) foam for enhanced thermal stability, flame retardancy and mechanical properties

Self-evolutionary recycling of flame-retardant polyurethane foam enabled by controllable catalytic cleavage

Polyurethane (PU) foams, pivotal in modern life, face challenges suh as fire hazards and environmental waste burdens. The current reliance of PU on potentially ecotoxic halogen-/phosphorus-based flame retardants impedes large-scale material recycling. Here, our demonstrated controllable catalytic cracking strategy, using cesium salts, enables self-evolving recycling of flame-retardant PU. The incorporation of cesium citrates facilitates efficient urethane bond cleavage at low temperatures (160 °C), promoting effective recycling, while encouraging pyrolytic rearrangement of isocyanates into char at high temperatures (300 °C) for enhanced PU fire safety. Even in the absence of halogen/phosphorus components, this foam exhibits a substantial increase in ignition time (+258.8%) and a significant reduction in total smoke release (-79%). This flame-retardant foam can be easily recycled into high-quality polyol under mild conditions, 60 °C lower than that for the pure foam. Notably, the trace amounts of cesium gathered in recycled polyols stimulate the regenerated PU to undergo self-evolution, improving both flame-retardancy and mechanical properties. Our controllable catalytic cracking strategy paves the way for the self-evolutionary recycling of high-performance firefighting materials.

Multiple free-radical-trapping and hydrogen-bonding-enhanced polyurethane foams with long-lasting flame retardancy, aging resistance, and toughness

Flexible polyurethane foam (FPUF) is a ubiquitous material utilized in furniture cushions, mattresses, and various technical applications. Despite the widespread use, FPUF faces challenges in maintaining long-lasting flame retardancy and aging resistance, particularly in harsh environments, while retaining mechanical robustness. Here, we present a novel approach to address these issues by enhancing FPUF through multiple free-radical-trapping and hydrogen-bonding mechanisms. A hindered amine phosphorus-containing polyol (DTAP) was designed and chemically introduced into FPUF. The distinctive synergy between hindered amine and phosphorus-containing structures enables the formation of multiple hydrogen bonds with urethane, while also effectively capturing free radicals across a broad temperature spectrum. As a result, incorporating only 5.1 wt% of DTAP led to the material successfully passing vertical burning tests and witnessing notable enhancements in tensile strength, elongation at break, and tear strength. Even after enduring accelerated thermal aging for 168 hours, the foam maintained exceptional flame retardancy and mechanical properties. This study offers novel insights into material enhancement, simultaneously achieving outstanding long-lasting flame retardancy, toughness, and anti-aging performance.

Study on the Influence of the Preparation Method of Konjac Glucomannan-Silica Aerogels on the Microstructure, Thermal Insulation, and Flame-Retardant Properties

Natural polysaccharides with high viscosity, good thermal stability, and biocompatibility can improve the mechanical properties of inorganic silica aerogels and enhance their application safety. However, the effects of the preparation methods of polysaccharide-silica aerogels on their microstructure and application properties have not been systematically studied. To better investigate the effect of the microstructure on the properties of aerogel materials, two aerogels with different structures were prepared using Konjac glucomannan (KGM) and tetraethoxysilane (TEOS) via physical blending (KTB) and co-precursor methods (KTC), respectively. The structural differences between the KTB and KTC aerogels were characterized, and the thermal insulation and fire-retardant properties were further investigated. The compressive strength of the KTC aerogels with a cross-linked interpenetrating network (IPN) structure was three times higher than that of the KTB aerogels, while their thermal conductivity was 1/3 of that of the KTB aerogels. The maximum limiting oxygen index (LOI) of the KTC aerogels was 1.4 times, the low peak heat release rate (PHRR) was reduced by 61.45%, and the lowest total heat release (THR) was reduced by 41.35% compared with the KTB aerogels. The results showed that the KTC aerogels with the IPN have better mechanical properties, thermal insulation, and fire-retardant properties than the simple physically blending KTB aerogels. This may be due to the stronger hydrogen-bonding interactions between KGM and silica molecules in the KTC aerogels under the unique forcing effect of the IPN, thus enhancing their structural stability and achieving complementary properties. This work will provide new ideas for the microstructure design of aerogels and the research of new thermal insulation and fire-retardant aerogels.

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.

MOF-derived 3D petal-like CoNi-LDH array cooperates with MXene to effectively inhibit fire and toxic smoke hazards of FPUF

The toxic smoke produced by the combustion of flexible polyurethane foam (FPUF) may not only caused casualties, but also polluted the environment. Here, double metal hydroxide derived from ZIF-67 (MOF-LDH) modified Ti₃C₂T_X (Ti₃C₂T_X@MOF-LDH) was innovatively designed to solve the serious smoke and fire hazards of FPUF. The FPUF nanocomposite containing 6 wt% Ti₃C₂Tx@MOF-LDH achieved a 16.1% reduction in total smoke production (TSP) along with 22.2% reduction in peak smoke production rate (PSPR), which greatly reduced the hazard of smoke. At the same time, toxic gases, such as carbon monoxide (CO), carbon dioxide (CO₂), and aromatic compounds, showed the same reduction pattern. In addition, the heat release of FPUF nanomaterials was also suppressed. In particular, the FPUF/Ti₃C₂Tx@MOF-LDH 3.0 achieved 110.4% and 76.1% increase in compressive strength and tensile strength, respectively, confirming the effective mechanical enhancement. Therefore, this work provided a new reference for the preparation of high-performance FPUF nanocomposites with low smoke, low fire hazard and excellent mechanical properties.

Functionalizing Ti3C2Tx for enhancing fire resistance and reducing toxic gases of flexible polyurethane foam composites with reinforced mechanical properties

Flexible polyurethane foam (FPUF) is the most used polyurethane, but the highly flammable characteristic limits its widespread usage. In this work, ZIF-8@Ti₃C₂T_xwas synthesized to reduce the heat and toxic gases of FPUF. Flame-retardant FPUF was characterized by cone calorimeter (Cone), thermogravimetric analysis/fourier-transform infrared spectroscopy (TG-FTIR), tensileand compression tests. Compared with pure FPUF, these results showed that the peak of heat release rate (PHRR), total heat release (THR), CO and HCN of FPUF6 decreased by 46%, 69%, 27% and 43.5%, respectively. Moreover, the tensile and compression strength of FPUF6 demonstrated a 52% and 130% increment, respectively. The superior dual metal catalytical charring-forming effect and physical barrier effect of ZIF-8@Ti₃C₂T_x were achieved. In summary, a simple and reliable strategy for preparing flame-retardant FPUF with reinforced mechanical and fire safety properties was provided.