Trilayer (TL) thin films of sodium montmorillonite (MMT), poly(allylamine hydrochloride) (PAH) and poly(sodium phosphate) (PSP), prepared via layer-by-layer assembly, completely prevent the melting of open-celled, flexible polyurethane foam when exposed to the direct flame from a butane torch. This work combines two common flame-retarding components, MMT clay and phosphorous (PSP), into one system in the presence of a blowing agent (PAH) and provides a foundational platform for new environmentally benign flame retardant strategies for polyurethane foams. QCM measurements confirm the presence of PSP within this novel trilayer nanocoating, which is effectively a nanobrick wall structure comprised of multilayers of exfoliated clay platelets that are intercalated with an intumescent polymeric mortar. Cone calorimetry confirmed all 10 TL coated foam reduces peak heat release rate by at least 50% relative to the uncoated control. SEM images reveal coatings swell around urethane walls to suppress flame spread and reduce heat transfer.

Intumescent nanobrick walls for fire protection of polyurethane foam

245th National Meeting (2013)

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