Newly developed trilayer thin films of sodium montmorillonite (MMT), poly(allylamine hydrochloride) (PAH) and poly(sodium phosphate) (PSP), prepared via layer-by-layer assembly, completely stop melting of open-celled flexible polyurethane foam when exposed to direct flame of a butane torch. QCM and EDX measurements confirm presence of PSP within this novel trilayer nanocoating, transforming traditional nanobrickwall systems into multilayers of exfoliated clay platelets that are intercalated with intumescent polymeric mortar. Cone calorimetry confirmed all 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. Using layer-by-layer assembly, 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 treatments for polyurethane foam.

Nanobrick walls intercalated with intumescent polymeric mortar create hybrid flame-retardant nanocoatings for foam

247th National Meeting (2014)

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