Effects of Dimethyl Methylphosphonate, Aluminum Hydroxide, Ammonium Polyphosphate, and Expandable Graphite on the Flame Retardancy and Thermal Properties of Polyisocyanurate–Polyurethane Foams

Optimisation of Additives to Maximise Performance of Expandable Graphite-Based Intumescent-Flame-Retardant Polyurethane Composites

The effect of varying the weight percentage composition (wt.%) of low-cost expandable graphite (EG), ammonium polyphosphate (APP), fibreglass (FG), and vermiculite (VMT) in polyurethane (PU) polymer was studied using a traditional intumescent flame retardant (IFR) system. The synergistic effect between EG, APP, FG, and VMT on the flame retardant properties of the PU composites was investigated using SEM, TGA, tensile strength tests, and cone calorimetry. The IFR that contained PU composites with 40 wt.% EG displayed superior flame retardant performance compared with the composites containing only 20 w.t.% or 10 w.t.% EG. The peak heat release rate, total smoke release, and carbon dioxide production from the 40 wt.% EG sample along with APP, FG, and VMT in the PU composite were 88%, 93%, and 92% less than the PU control sample, respectively. As a result, the synergistic effect was greatly influenced by the compactness of the united protective layer. The PU composite suppressed smoke emission and inhibited air penetrating the composite, thus reducing reactions with the gas volatiles of the material. SEM images and TGA results provided positive evidence for the combustion tests. Further, the mechanical properties of PU composites were also investigated. As expected, compared with control PU, the addition of flame-retardant additives decreased the tensile strength, but this was ameliorated with the addition of FG. These new PU composite materials provide a promising strategy for producing polymer composites with flame retardation and smoke suppression for construction materials.

Sunflower Oil as a Renewable Resource for Polyurethane Foams: Effects of Flame-Retardants

Currently, polyurethane (PU) manufacturers seek green alternatives for sustainable production. In this work, sunflower oil is studied as a replacement and converted to a reactive form through epoxidation and oxirane opening to produce rigid PU foams. Confirmatory tests such as Fourier-transform infrared spectroscopy (FT-IR), gel permeation chromatography (GPC), and hydroxyl value among others were performed to characterize the synthesized polyol. Despite the versatility of rigid PU foams, they are highly flammable, which makes eco-friendly flame retardants (FRs) desired. Herein, expandable graphite (EG) and dimethyl methyl phosphonate (DMMP), both non-halogenated FR, were incorporated under different concentrations to prepare rigid PU foams. Their effects on the physio-mechanical and fire-quenching properties of the sunflower oil-based PU foams were elucidated. Thermogravimetric and compression analysis showed that these foams presented appreciable compressive strength along with good thermal stability. The closed-cell contents (CCC) were around 90% for the EG-containing foams and suffered a decrease at higher concentrations of DMMP to 72%. The burning test showed a decrease in the foam's flammability as the neat foam had a burning time of 80 s whereas after the addition of 13.6 wt.% of EG and DMMP, separately, there was a decrease to 6 and 2 s, respectively. Hence, our research suggested that EG and DMMP could be a more viable alternative to halogen-based FR for PU foams. Additionally, the adoption of sunflower polyol yielded foams with results comparable to commercial ones.

Acoustic Performance and Flame Retardancy of Ammonium Polyphosphate/Diethyl Ethylphosphonate Rigid Polyurethane Foams

Flame-retardant water-blown rigid polyurethane foams (RPUFs) modified by ammonium polyphosphate (APP) and diethyl ethylphosphonate (DEEP) were synthesized by a one-pot free-rising method. We performed scanning electron microscopy (SEM), compression strength tests, acoustic absorption measurements and thermogravimetric analysis, as well as limited oxygen index, vertical burning and cone calorimeter tests to investigate the mechanical properties, acoustic performance and flame retardancy of the foams. SEM confirmed that the open-cell structures of the foams were successfully constructed with the introduction of a cell-opening agent. Upon using 20 php APP, the average acoustic absorption coefficient of the foam reached 0.535 in an acoustic frequency range of 1500-5000 Hz. The results of thermogravimetric analysis demonstrated that the incorporation of APP and DEEP can effectively restrain mass loss of RPUFs during pyrolysis. In particular, the compressive strength of a foam composite containing 5 php APP and 15 php DEEP increased to 188.77 kPa and the LOI value reached 24.9%. In a vertical burning test and a cone calorimeter test, the joint use of APP and DEEP endowed RPUFs with a V-0 rating and they attained a THR value of 23.43 MJ/m². Moreover, the addition of APP improved the acoustic absorption performance of the foam, verified by acoustic absorption measurements. Considering potential applications, the formulation containing 15 php APP and 5 php DEEP could be used in the preparation of a new flame-retardant acoustic absorption rigid polyurethane foam.

The improvement of fire safety performance of flexible polyurethane foam by Highly-efficient P-N-S elemental hybrid synergistic flame retardant

Herein, three different phosphorus-containing compounds (methyl phosphoryl dichloride, phenyl phosphoryl dichloride and phenyl dichlorophosphate) were reacted with 2-aminobenzothiazole respectively, and a series of synergistic flame retardants with phosphorus, nitrogen and sulfur elements were synthesized, named MPBT, PPBT and POBT respectively. Then, they were added to prepare flame-retardant flexible polyurethane foam (FPUF). Through the analysis of thermal stability, pyrolysis, heat release and smoke release behavior, the influence of different phosphorus-containing structures on the flame-retardant performance of FPUF was studied, and their flame-retardant mechanism was explored in detail. Among them, MPBT had the highest flame retardant efficiency with the same addition amount (10 wt%). The limiting oxygen index (LOI) value of PU/10.0% MPBT reached 22.5 %, and it successfully passed the vertical burning test. Subsequently, the addition amount of MPBT was increased and the best comprehensive performance of flame-retardant FPUF was explored. The results showed that the LOI value of PU/15.0% MPBT was increased to 23.5%. As for PU/15.0% MPBT, the peak heat release rate (PHRR) was 453 KW/m², which was reduced by 46.64 %; and the flame retardancy index (FRI) value was also increased to 6.88. At the same time, the mechanical properties of flame-retardant FPUF were studied. The tensile strength of PU/15.0% MPBT reached 170 KPa, and the permanent deformation of FPUF/10% MPBT was only 4 %, showing its excellent resilience. The above results show that this phosphorus-containing element hybrid synergistic flame retardant (MPBT) has a very good application prospect in the field of flame-retardant polymer materials.

Effect of Evening Primrose (Oenothera biennis) Oil Cake on the Properties of Polyurethane/Polyisocyanurate Bio-Composites

Rigid polyurethane/polyisocyanurate (RPU/PIR) foam formulations were modified by evening primrose (Oenothera biennis) oil cake as a bio-filler in the amount of 5 to 50 wt.%. The obtained foams were tested in terms of processing parameters, cellular structure (SEM analysis), physico-mechanical properties (apparent density, compressive strength, brittleness, accelerated aging tests), thermal insulation properties (thermal conductivity coefficient, closed cells content, absorbability and water absorption), flammability, smoke emission, and thermal properties. The obtained results showed that the amount of bio-filler had a significant influence on the morphology of the modified foams. Thorough mixing of the polyurethane premix allowed better homogenization of the bio-filler in the polyurethane matrix, resulting in a regular cellular structure. This resulted in an improvement in the physico-mechanical and thermal insulation properties as well as a reduction in the flammability of the obtained materials. This research provided important information on the management of the waste product from the edible oil industry and the production process of fire-safe RPU/PIR foams with improved performance properties. Due to these beneficial effects, it was found that the use of evening primrose oil cake as a bio-filler for RPU/PIR foams opens a new way of waste management to obtain new “green” materials.

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.

Flame retardant and smoke-suppressant rigid polyurethane foam based on sodium alginate and aluminum diethylphosphite

In order to improve the flame-retardant effect and thermal behaviour of rigid polyurethane foam (RPUF), the flame retardancy of sodium alginate (SA), aluminium diethyl phosphite (ADPO₂) and expandable graphite (EG) were proposed. First, the structures of RPUF with or without flame retardancy were confirmed by scanning electron microscopy (SEM). Additionally, the combustion behaviours and thermal performance of the flame-retardant polyurethane were evaluated through thermogravimetric analysis (TGA), limiting oxygen index (LOI) tests, and UL-94 tests. Finally, the cone calorimeter results reveled the RPUF/5ADPO₂/7.5SA/7.5EG exhibit excellent thermodynamic properties. The results of the heat release rate (HRR), total heat release (THR), total smoke production (TSP), and smoke production rate (SPR) could demonstrate the smoke-suppressant and flame-retardant of polyurethane. The system of RPUF/ADPO₂/SA/EG showed excellent flame-retardant in polyurethane.

Flame-retardant ethylene vinyl acetate composite materials by combining additions of aluminum hydroxide and melamine cyanurate: Preparation and characteristic evaluations

There is a great interest to develop efficient fire-resistant materials. While ethylene vinyl acetate (EVA) is a widely used material, it suffers from the problem of relatively high inflammability which seriously hinders its usage as the product material with a high flame-retardant requirement. In this study, a strategy to combine aluminum hydroxide (ATH) and melamine cyanurate (MCA) with EVA was proposed to prepare the EVA composite materials with high flame resistance. It was found that slight addition of MCA could increase the lubricity of EVA and raise the compatibility between EVA and ATH. Thermogravimetric analysis (TGA) indicated that the thermal stability of EVA was improved via adding MCA, which was evidenced by the delayed thermal decomposition temperature. Moreover, the combustion results indicated that the EVA composite with 60 parts per hundred (phr) ATH and 40 phr MCA addition (EVA-60-40) displayed the optimal isolated layer favoring the fire resistance. In addition, the highest limiting oxygen index (LOI) value (27.5%) and V-0 rating of the EVA-60-40 as compared with other components indicated its incombustible nature. These results suggested the synergetic effect of ATH and MCA additions, the high efficiency of the proposed strategy and the wide application prospect of the produced EVA-ATH-MCA composite materials.

Preparation of Flame-Retardant Rigid Polyurethane Foams by Combining Modified Melamine-Formaldehyde Resin and Phosphorus Flame Retardants

In this work, ethylene glycol-modified melamine-formaldehyde resin (EMF) was synthesized from ethylene glycol, paraformaldehyde, and melamine, and then rigid polyurethane foams (RPUFs) were prepared using EMF, polyols and polyisocyanate. The effects of ammonium polyphosphate (APP) and dimethyl methylphosphonate (DMMP) on the flame retardancy, mechanical properties, thermal stability, and morphology of the prepared RPUFs were studied. It is shown that the flame-retardant performance of EMF-filled RPUFs can be enhanced by the addition of APP and DMMP. Thus, APP and DMMP can synergistically improve the flame retardancy of RPUFs. APP has good smoke suppression, while DMMP can increase the total smoke production and CO/CO2 weight ratio during the combustion of RPUFs.

Enhancing Flame Retardancy, Thermal Stability, Physical and Mechanical Properties of Polyethylene Foam with Polyphosphate Modified Expandable Graphite and Ammonium Polyphosphate

The method of preparing polyolefin foam with good flame retardancy, thermal stability, and physical and mechanical properties was investigated. Foaming condition of linear low density polyethylene (LLDPE) was investigated with triphenyl phosphate (TPP) as plasticizer, NaHCO3 as foaming agent. The influence of modified expandable graphite (EGP) and ammonium polyphosphate (II) on foam density, compression strength, combustion characteristics and thermal stability was explored. Results verified that EGP presented better dilatability and flame retardancy than the normal expandable graphite. Addition of EGp improved the limiting oxygen index (LOI) of 15NaHCO3/100 LLDPETPP/30EGp foam from 18.8% to 24.6%. Furthermore, the combination of EGp and ammonium polyphosphate (II) (APP) at the mass ratio of 2:1 improved the LOI of 15NaHCO3/100 LLDPETPP/20EGp/10APP sample to 27.9%, and the vertical burning UL-94 level reached V-0, indicating that this material was flame retardant. Although these additives made 15NaHCO3/100 LLDPETPP/20EGp/10APP composite exhibit a high density of 142.5 kg m−3, which was increased by 12.3 wt% relative to the 15NaHCO3/100 LLDPETPP foam, it could improve the compressive strength to 0.4747 MPa, which was about 2.7 times that of the matrix. The thermal stability of the material was also enhanced.

Influence of the Characteristics of Expandable Graphite on the Morphology, Thermal Properties, Fire Behaviour and Compression Performance of a Rigid Polyurethane Foam

Three types of expandable graphite (EG) differing in particle size and expansion volume, are compared as flame retardant additives to rigid polyurethane foams (RPUFs). In this paper we discuss microstructure, thermal stability, fire behavior, and compression performance. We find that ell size distributions were less homogeneous and cell size was reduced. Furthermore, thermal conductivity increased along with EG loading. Thermogravimetric analysis (TGA) showed that EG only increased residue yield differently. The results indicate that a higher expansion of EG increased the limiting oxygen index (LOI) value, whereas a bigger particle size EG improved the rating of the vertical burning test (UL94). Results from the cone calorimeter test showed that a bigger particle size EG effectively reduced peak of heat release rate (pHRR). Furthermore, a higher expansion, led to a decrease in smoke production (TSP). The combination of both characteristics gives extraordinary results. The physical–mechanical characterization of the EG/RPUF foams revealed that their compression performance decreased slightly, mostly due to the effect of a bigger size EG.

Effects of hydrotalcite on rigid polyurethane foam composites containing a fire retarding agent: compressive stress, combustion resistance, sound absorption, and electromagnetic shielding effectiveness

Polyether polyol, isocyanate, and a flame retardant (10 wt%), hydrotalcite (0, 1, 3, 5, 7, and 9 wt%) are used to form a rigid PU foam, while a nylon nonwoven fabric (400 g m⁻²) and a polyester aluminum foil are combined to serve as the panel. The rigid PU foam and the panel are then combined to form the rigid foam composites. The cell structure, compressive stress, combustion resistance, thermal stability, sound absorption, and electromagnetic shielding effectiveness of the rigid foam composites are evaluated, examining the effects of using hydrotalcite. When the hydrotalcite is 5 wt%, the rigid foam composites have an optimal density of 0.168 g cm⁻³, an average cell size of 0.2858 mm, a maximum compressive stress of 479.95 kpa, an optimal LOI of 29, an optimal EMSE of 45 dB, and the maximum thermal stability and sound absorption.

The synthesis of rigid polyurethane foam.

The pyrolysis behaviors of phosphorus-containing organosilicon compound modified ammonium polyphosphate with different phosphorus-containing groups, and their different flame-retardant mechanisms in polyurethane foam

Two phosphorus-containing organosilicon compounds (PCOCs) with similar structure but different phosphorus-containing groups (phenyl phosphate group, PCOC1; phenylphosphoryl group, PCOC2) were synthesized. They were used to modify ammonium polyphosphate (APP), and the products obtained were coded as MAPP1 and MAPP2. Then MAPP1 and MAPP2 were respectively incorporated into low-density rigid polyurethane foam (LD-RPUF). The pyrolysis behavior of these two kinds of MAPP was investigated. Results showed that PCOC2, with the phenylphosphoryl group, induced the decomposition of APP, leading to early and rapid decomposition of MAPP2 with the release of NH₃ in a short time and the formation of crosslinked structure quickly. Simultaneously, the phosphorus of MAPP2 was all retained in the condensed phase. In contrast, PCOC1, with the phenyl phosphate group, also induced the decomposition of APP. However, not all the phosphorus-containing groups of MAPP1 were retained in the condensed phase; some of the phosphorus was released into the gas phase in the form of PO₂· and PO· free radicals. Evaluation of the flame-retardant effect by means of the cone calorimeter test demonstrated that MAPP2 had better flame-retardant properties in the LD-RPUF system, including the reduction of peak heat release rate, total heat release, and total smoke release. Moreover, the char yield of LD-RPUF/MAPP2 was more than that of LD-RPUF/MAPP1. Macro and micro photographs showed that MAPP2 can promote the LD-RPUF matrix to form an intumescent char layer with more complete and stable foam during the combustion process compared with MAPP1. Finally, a possible flame-retardant mechanism of MAPP1 and MAPP2 in LD-RPUF is proposed.

The centralized release of nonflammable gas and quick formation of crosslinked structure increase the flame retardant properties of polyurethane foams.

Interfacial engineering of renewable metal organic framework derived honeycomb-like nanoporous aluminum hydroxide with tunable porosity

Novel honeycomb-like mesoporous aluminum hydroxide (pATH) was synthesized via a facile one-step reaction by employing ZIF-8 as a template.

Novel honeycomb-like mesoporous aluminum hydroxide (pATH) was synthesized via a facile one-step reaction by employing ZIF-8 as a template. This self-decomposing template was removed automatically under acidic conditions without the need for any tedious or hazardous procedures. Meanwhile, the pore size of pATH was easily modulated by tuning the dimensions of the ZIF-8 polyhedrons. Of paramount importance was the fact that the dissolved ZIF-8 in solution was regenerated upon deprotonation of the ligand under mild alkali conditions, and was reused in the preparation of pATH, thus forming a delicate synthesis cycle. The renewable template conferred cost-effective and sustainable features to the as-synthesized product. As a proof-of-concept application, the fascinating nanoporous structure enabled pATH to load more phosphorous-containing flame retardant and endowed better interaction with epoxy resin over that of commercial aluminum hydroxide. The limiting oxygen index, UL-94 vertical burning test and cone calorimeter test showed that the results of epoxy with the modified pATH rivalled those of epoxy with two times the loading amount of the commercial counterpart, while the former presented better mechanical properties. The proposed “amorphous replica method” used in this work will advance the potential for launching a vast area of research and technology development for the preparation of porous metal hydroxides for use in practical applications.

Recent studies on the decomposition and strategies of smoke and toxicity suppression for polyurethane based materials

This review provides insight into recent studies related to thermal degradation, smoke and toxicity production and their reduction strategies for polyurethane-based materials.