Flame-Retardant Flexible Polyurethane Foams with Highly Efficient Melamine Salt

Catalytic polymer self-cleavage for CO2 generation before combustion empowers materials with fire safety

Polymeric materials, rich in carbon, hydrogen, and oxygen elements, present substantial fire hazards to both human life and property due to their intrinsic flammability. Overcoming this challenge in the absence of any flame-retardant elements is a daunting task. Herein, we introduce an innovative strategy employing catalytic polymer auto-pyrolysis before combustion to proactively release CO2, akin to possessing responsive CO2 fire extinguishing mechanisms. We demonstrate that potassium salts with strong nucleophilicity (such as potassium formate/malate) can transform conventional polyurethane foam into materials with fire safety through rearrangement. This transformation results in the rapid generation of a substantial volume of CO2, occurring before the onset of intense decomposition, effectively extinguishing fires. The inclusion of just 1.05 wt% potassium formate can significantly raise the limiting oxygen index of polyurethane foam to 26.5%, increase the time to ignition by 927%, and tremendously reduce smoke toxicity by 95%. The successful application of various potassium salts, combined with a comprehensive examination of the underlying mechanisms, underscores the viability of this strategy. This pioneering catalytic approach paves the way for the efficient and eco-friendly development of polymeric materials with fire safety.

Porous Thermal Insulation Polyurethane Foam Materials

Porous thermal insulation materials (PTIMs) are a class of materials characterized by low thermal conductivity, low bulk density and high porosity. The low thermal conductivity of the gas enclosed in their pores allows them to achieve efficient thermal insulation, and are they among the most widely used and effective materials in thermal insulation material systems. Among the PTIMs, polyurethane foam (PUF) stands out as particularly promising. Its appeal comes from its multiple beneficial features, such as low density, low thermal conductivity and superior mechanical properties. Such attributes have propelled its broad application across domains encompassing construction, heterogeneous chemical equipment, water conservation and hydropower, and the aviation and aerospace fields. First, this article outlines the structure and properties of porous thermal insulation PUF materials. Next, it explores the methods of preparing porous thermal insulation PUF materials, evaluating the associated advantages and disadvantages of each technique. Following this, the mechanical properties, thermal conductivity, thermal stability, and flame-retardant characteristics of porous thermal insulation PUF materials are characterized. Lastly, the article provides insight into the prospective development trends pertaining to porous thermal insulation PUF materials.

Flame-Retardant and Smoke-Suppressant Flexible Polyurethane Foams Based on Phosphorus-Containing Polyester Diols and Expandable Graphite

A liquid-phosphorus-containing polyester diol, PPE, was prepared via condensation polymerization using commercial reactive flame retardant 9,10-dihydro-10-[2,3-di(hydroxycarbonyl)propyl]-10-phospha-phenanthrene-10-oxide, adipic acid, ethylene glycol, and 1,4-butanediol. PPE and/or expandable graphite (EG) were then incorporated into phosphorus-containing flame-retardant polyester-based flexible polyurethane foams (P-FPUFs). The structure and properties of the resultant P-FPUFs were characterized using scanning electron microscopy tensile measurements, limiting oxygen index (LOI), vertical burning tests, cone calorimeter tests, thermogravimetric analysis coupled with Fourier-transform infrared spectroscopy, X-ray photoelectron spectroscopy, and Raman spectroscopy. Unlike the FPUF prepared using regular polyester polyol (R-FPUF), PPE increased the flexibility and elongation at break of the resultant forms. More importantly, the peak heat release rate (PHRR) and total heat release (THR) of P-FPUF were reduced by 18.6% and 16.3%, respectively, via gas-phase-dominated flame-retardant mechanisms, compared with those of R-FPUF. The addition of EG further reduced the peak smoke production release (PSR) and total smoke production (TSP) of the resultant FPUFs while increasing the LOI and char formation. Interestingly, it was observed that EG noticeably improved the residual quantity of phosphorus in the char residue. When the EG loading was 15 phr, the resulting FPUF (P-FPUF/15EG) attained a high LOI value (29.2%) and exhibited good anti-dripping performance. Meanwhile, the PHRR, THR, and TSP of P-FPUF/15EG were significantly decreased by 82.7%, 40.3%, and 83.4%, respectively, compared with those of P-FPUF. This superior flame-retardant performance can be attributed to the combination of the bi-phase flame-retardant behavior of PPE and condensed-phase flame-retardant characteristics of EG.

Emerging trends in flame retardancy of rigid polyurethane foam and its composites: A review

Owing to the superior thermal insulating attributes of rigid polyurethane foam (RPUF) compared to other insulating materials (expanded and extruded polystyrene, mineral wool), it remains the most dominant insulating material and most studied polymer foam. Like other polyurethane foam, RPUF is highly flammable, necessitating the incorporation of flame retardants (FR) during production to lower combustibility, promoting its continuous use as insulation material in construction, transportation, and others. The popular approaches for correcting the high flammability of RPUF are copolymerization and blending (with FR). The second method has proven to be most effective as there are limited trade-offs in RPUF properties. Meanwhile, the high flammability of RPUF is still a significant hindrance in emerging applications (sensors, space travel, and others), and this has continuously inspired research in the flame retardancy of RPUF. In this study, properties, and preparation methods of RPUF are described, factors responsible for the high flammability of PUF are discussed, and flame retardancy of RPUF is thoroughly reviewed. Notably, most FR for RPUF are inorganic nanoparticles, lignin, intumescent FR systems of expandable graphite (EG), ammonium polyphosphate (APP), and hybridized APP or EG with other FR. These could be due to their ease of processing, low cost, and being environmentally benign. Elaborate discussion on RPUF FR mechanisms were also highlighted. Lastly, a summary and future perspectives in fireproofing RPUF are provided, which could inspire the design of new FR for RPUF.

Epoxy/melamine polyphosphate modified silicon carbide composites: Thermal conductivity and flame retardancy analyses

Silicon carbide (SiC) was modified by melamine polyphosphate (MPP)-modified silicone to form SiC-MPP, then incorporated into epoxy resin (EP) for developing thermally resistant composites, which showed thermal conductivity and flame retardancy performance. The EP/SiC-MPP composites were prepared by blending and cured under 60°C for 2 h and 150°C for 8 h. The grafting degree of SiC-MPP was analyzed using Fourier transform Infrared, scanning electron microscope, and thermogravimetric measurements. The flame retardancy of the EP/SiC-MPP composites was studied by UL-94 vertical combustion and cone calorimetry test. The results showed that for EP/SiC-MPP containing 20 wt%, the UL-94 was case V1. Also compared to pure epoxy, the peak heat release rate (PHRR) of composites was reduced from 800 to 304 kW·m−2. The thermal conductivity of EP/SiC-M20 composites was 0.53 W·m−1·K−1, almost 2.5-fold higher than pure epoxy (0.21 W·m−1·K−1). The as-prepared EP/SiC-MPP composites exhibited enhanced flame retardancy and thermal conductivity. Based on analyses performed, these composites took credit-related applications.

Improvement the Flame Retardancy and Thermal Conductivity of Epoxy Composites via Melamine Polyphosphate-Modified Carbon Nanotubes

Surface chemical modification of carbon nanotubes can enhance the compatibility with polymers and improve flame retardancy performances. In this work, the double bond active sites were constructed on the surface of carbon nanotubes modified by the γ-methacryloyloxypropyl trimethoxysilane (KH570). Glycidyl methacrylate (GMA) was further grafted onto the surface of carbon nanotubes via free radical polymerization. Finally, the flame retardant melamine polyphosphate (MPP) was bonded to the surface of carbon nanotubes by the ring-opening reaction. This modification process was proved to be achieved by infrared spectroscopy and thermogravimetric test. The carbon nanotubes modified by flame retardant were added into the epoxy matrix and cured to prepare flame retardant and thermal conductive composites. The flame retardancy of composites were studied by cone calorimetry, UL94 vertical combustion test and limiting oxygen index. The thermal conductivity of composites was characterized by laser thermal conductivity instrument. The results showed that when the addition amount of flame retardant MPP-modified carbon nanotubes in composites was 10 wt%, the flame retardant level of UL94 reached to V2, the limiting oxygen index increased from 25.1 of pure epoxy resin to 28.3, the PHRR of pure epoxy resin was reduced from 800 kW/m² to 645 kW/m² of composites and thermal conductivity of composites was enhanced from 0.21 W/m·K⁻¹ of pure epoxy resin to 0.42 W/m·K⁻¹ of the composites.

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.

Coupling Suspect and Nontarget Screening with Mass Balance Modeling to Characterize Organic Micropollutants in the Onondaga Lake-Three Rivers System

Characterizing the occurrence, sources, and fate of organic micropollutants (OMPs) in lake-river systems serves as an important foundation for constraining the potential impacts of OMPs on the ecosystem functions of these critical landscape features. In this work, we combined suspect and nontarget screening with mass balance modeling to investigate OMP contamination in the Onondaga Lake-Three Rivers system of New York. Suspect and nontarget screening enabled by liquid chromatography-high-resolution mass spectrometry led to the confirmation and quantification of 105 OMPs in water samples collected throughout the lake-river system, which were grouped by their concentration patterns into wastewater-derived and mixed-source clusters via hierarchical cluster analysis. Four of these OMPs (i.e., galaxolidone, diphenylphosphinic acid, N-butylbenzenesulfonamide, and triisopropanolamine) were prioritized and identified by nontarget screening based on their characteristic vertical distribution patterns during thermal stratification in Onondaga Lake. Mass balance modeling performed using the concentration and discharge data highlighted the export of OMPs from Onondaga Lake to the Three Rivers as a major contributor to the OMP budget in this lake-river system. Overall, this work demonstrated the utility of an integrated screening and modeling framework that can be adapted for OMP characterization, fate assessment, and load apportionment in similar surface water systems.

Melamine-based functionalized graphene oxide and zirconium phosphate for high performance removal of mercury and lead ions from water

Heavy metal ions are highly toxic and widely spread as environmental pollutants. This work reports the development of two novel chelating adsorbents, based on the chemical modifications of graphene oxide and zirconium phosphate by functionalization with melamine-based chelating ligands for the effective and selective extraction of Hg(ii) and Pb(ii) from contaminated water sources. The first adsorbent melamine, thiourea-partially reduced graphene oxide (MT-PRGO) combines the heavier donor atom sulfur with the amine and triazine nitrogen's functional groups attached to the partially reduced GO nanosheets to effectively capture Hg(ii) ions from water. The MT-PRGO adsorbent shows high efficiency for the extraction of Hg(ii) with a capacity of 651 mg g-1 and very fast kinetics resulting in a 100% removal of Hg(ii) from 500 ppb and 50 ppm concentrations in 15 second and 30 min, respectively. The second adsorbent, melamine zirconium phosphate (M-ZrP), is designed to combine the amine and triazine nitrogen's functional groups of melamine with the hydroxyl active sites of zirconium phosphate to effectively capture Pb(ii) ions from water. The M-ZrP adsorbent shows exceptionally high adsorption affinity for Pb(ii) with a capacity of 681 mg g-1 and 1000 mg g-1 using an adsorbent dose of 1 g L-1 and 2 g L-1, respectively. The high adsorption capacity is also coupled with fast kinetics where the equilibrium time required for the 100% removal of Pb(ii) from 1 ppm, 100 ppm and 1000 ppm concentrations is 40 seconds, 5 min and 30 min, respectively using an adsorbent dose of 1 g L-1. In a mixture of six heavy metal ions at a concentration of 10 ppm, the removal efficiency is 100% for Pb(ii), 99% for Hg(ii), Cd(ii) and Zn(ii), 94% for Cu(ii), and 90% for Ni(ii) while at a higher concentration of 250 ppm the removal efficiency for Pb(ii) is 95% compared to 23% for Hg(ii) and less than 10% for the other ions. Because of the fast adsorption kinetics, high removal capacity, excellent regeneration, stability and reusability, the MT-PRGO and M-ZrP are proposed as top performing remediation adsorbents for the solid phase extraction of Hg(ii) and Pb(ii), respectively from contaminated water.

Novel MoS2-DOPO Hybrid for Effective Enhancements on Flame Retardancy and Smoke Suppression of Flexible Polyurethane Foams

A novel MoS₂-DOPO hybrid has been successfully synthesized through the grafting of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) on the surface of MoS₂ nanosheets using allyl mercaptan as an intermediate. MoS₂-DOPO was used as a flame retardant additive to prepare flame-retardant flexible polyurethane foam (FPUF). The influence of MoS₂-DOPO on the mechanical, thermal stability, and flame retardancy properties of FPUF composites were systematically investigated. The incorporation of MoS₂-DOPO could not deteriorate greatly the tensile strength and 50% compression set of FPUF composites, but effectively improves the char residue. The cone calorimeter and smoke density tests results revealed that the peak heat release rate, total heat release, and the maximum smoke density of the MoS₂-DOPO/FPUF composite were reduced by 41.3, 27.7, and 40.5%, respectively, compared with those of pure FPUF. Furthermore, the char residue after cone calorimeter tests and pyrolysis gaseous products of the MoS₂-DOPO/FPUF composite were analyzed by scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, and thermogravimetric analysis/infrared spectrometry. The results suggested that the MoS₂-DOPO hybrid played a synergistic flame retardant effect of gas and condensed bi-phase action. In addition, a possible flame retardancy and smoke suppression mechanism of the MoS₂-DOPO/FPUF composite were proposed. This study provides a facile and promising strategy for the fabrication of polymer materials with excellent flame retardancy and smoke suppression properties.

Modification of diatomite with melamine coated zeolitic imidazolate framework-8 as an effective flame retardant to enhance flame retardancy and smoke suppression of rigid polyurethane foam

In this work, the core-shell structure (ZIF-8@MA) was prepared first with melamine (MA) coated zeolitic imidazolate framework-8 (ZIF-8), and the ternary composite ZMD containing Si-N-Zn was successfully synthesized with the diatomite modified ZIF-8@MA. Subsequently, the prepared ZMD was added into rigid polyurethane foam (RPUF) to investigate its effect on fire safety of RPUF. The results of cone calorimeter and limiting oxygen index (LOI) tests indicated that ZMD effectively reduced the fire hazard of RPUF. This was because of the physical barrier effect of diatomite, the co-catalyzed char formation in the condensed phase of ZnO produced by the decomposition of ZIF-8 and silica produced by the decomposition of diatomite, and the gas phase effect of MA that enabled RPUF to achieve excellent flame retardancy and smoke suppression. The specific mechanism of flame retardancy and smoke suppression of ZMD for RPUF was also discussed in this study.

Thermal Stability, Pyrolysis Behavior, and Fire-Retardant Performance of Melamine Cyanurate@Poly(cyclotriphosphazene-co-4,4'-sulfonyl diphenol) Hybrid Nanosheet-Containing Polyamide 6 Composites

A novel halogen-free highly cross-linked supramolecular poly(cyclotriphosphazene-co-4,4'-sulfonyl diphenol) (PZS)-functionalized melamine cyanurate (MCA) (MCA@PZS) hybrid nanosheet fire-retardant (FR) was synthesized and thoroughly characterized using scanning electron microscopy, Fourier-transform infrared (FTIR), X-ray diffraction, and X-ray photoelectron spectroscopy analyses. The polyamide 6 (PA6) composites comprising MCA, PZS, and the MCA@PZS hybrids were prepared via the melt-blending technique. The thermogravimetric analysis combined with FTIR and mass spectroscopy revealed that during thermal degradation, the PA6/MCA@PZS composites released less toxic gases and small organic volatile compounds than the neat PA6 and composites containing MCA or PZS solely. Moreover, compared to neat PA6, the PA6 composite with a 5 wt % MCA@PZS hybrid exhibited enhanced fire retardation properties, with a 29.4 and 32.1% decrease in the peak heat and total heat release rates, respectively. Besides, the PA6 composites with MCA@PZS-5% content achieved a V-0 rating in the UL-94 test. Finally, based on the obtained results from gaseous and condensed phases, the possible mechanism responsible for improved FR properties of the PA6/MCA@PZS composites was proposed.

Intumescent Phosphorus and Triazole-Based Flame-Retardant Polyurethane Foams from Castor Oil

Synthesis of a novel phosphorus and triazole-functionalized flame-retardant (FR) monomer (PTFM) using azide-alkyne "click" reaction between triprop-2-ynyl phosphate and 2-azidoethanol that can impart intumescent FR property to polyurethane foams (PUFs) has been reported. Polyurethane triazole foams (PUTFs) were prepared using the as-synthesized PTFM and a hydroxylated castor polyol with a hydroxyl value of ∼310 mg KOH/g for application as reactive FR rigid foams. PTFM and the castor polyol were characterized for structural elucidation using Fourier transform infrared and ¹H, ¹³C, and ³¹P NMR. PUTFs with a varying loading content of PTFM were subjected to the lab-scale flame test, cone calorimetry test, Underwriters Laboratory 94 Vertical burning test (UL 94V), and limiting oxygen index (LOI) test. A significant increase in the char yields, reduction in heat release rates, V-1 rating, and 27% of LOI were observed for PUTFs compared to PUFs and proportional to the percentage loading of PTFM. The cumulative effect of nitrogen and phosphorus in PUTFs on their intumescent behavior was evident from the thermogravimetric analysis and scanning electron microscopy micrographs, which were further supplemented by X-ray photoelectron spectroscopy studies, indicating expulsion of N₂ and overall improvement in compression strength as well. Such environment-friendly reactive FRs can be good replacements to the halogenated ones.

Flame-retardant and smoke-suppressant flexible polyurethane foams based on reactive phosphorus-containing polyol and expandable graphite

In this manuscript, flame-retardant and smoke-suppressant flexible polyurethane foams (FPUFs) were designed and synthesized based on novel liquid phosphorus-containing polyol named as PDEO and expandable graphite (EG). The reactive PDEO can be chemically added into the chain of FPUF, while expandable graphite was blended into the matrix of foam through foaming process. Benefitting from the incorporation of reactive PDEO with a long chain, the resultant FPUF containing EG exhibited considerable mechanical properties. More importantly, the synergistic effect of PDEO and EG can endow FPUF with great flame retardancy, anti-driping performances. Furthermore, the resultant FPUF/EG/PDEO foams exhibit considerable smoke suppression performances. The vertical burning test revealed that the FPUF containing 5 php PDEO and 10 php EG extinguished quickly without dripping and kept the original shape after removing the igniter. The cone calorimeter results demonstrated that the synergistic effect of PDEO and EG can effectively reduce the heat release rate (HRR) and total release rate (THR) of the composite foam. Remarkably, the smoke production release (SPR), total smoke production (TSP), light transmission and specific optical density results indicated significantly smoke-suppressant properties of the composite foam. The mechanism analysis confirmed that the synergistic effect of gas-condensed bi-phase action from PDEO and EG contributed the great flame retardation of the composite foam. This novel FPUF provides a promising strategy for producing the polymer foam with flame retardation, smoke suppression and anti-dripping performances.

Novel Core-Shell Hybrid Nanosphere towards the Mechanical Enhancement and Fire Retardance of Polycarbonate

It is a huge challenge to achieve highly efficient fire retardance with no mechanical damage to polymers. In our current research, a novel core-shell titanium dioxide@diphenylphosphinic (TiO₂@DPP) nanosphere was first synthesized through a hydrothermal reacting process, and applied in simultaneously enhancing the fire retardance and mechanical properties of polycarbonate (PC). The well-designed TiO₂@DPP exhibited a significant effect on combustion performance and mechanical reinforcement of PC. At only 0.10 wt % of TiO₂@DPP, PC/TiO₂@DPP passed the UL-94 V-0 rating, and its oxygen index value rose to 29.3%. Moreover, the peak value of the heat release rate was remarkably decreased by 34.1% in the combustion test, accompanied by the formation of more compacted char layer and the release of more incombustible gas. Equally important another aspect is that the PC containing only 0.10 wt % of TiO₂@DPP possessed higher elongation at break and higher tensile strength than pure PC, correspondingly increased by 27.7 and 14.7%. The analysis of the flame-retardant mechanism revealed that the improved fire retardance of PC is primarily ascribed to the barrier action of a cross-linking network containing phosphorus and titanium, the dilution of nonflammable gases such as H₂O, and the quenching effect of free radicals which are from the phosphorous group in the gas phase. All these experimental results demonstrate that the core-shell hybrid TiO₂@DPP may achieve a simultaneous significant improvement in fire retardance and mechanical properties of PC.