Established layer-by-layer (LbL) flame retardant mechanisms have been combined to produce a ‘stacked’ nanocoating for flame retarding polyurethane foam. A bilayer system of chitosan (CH) and vermiculite (VMT) clay provides a base layer, protecting the polyurethane long enough for a charring system of CH and ammonium polyphosphate (APP) to activate and form an enhanced char layer via intumescence. Stacking these two recipes allows the foam to self-extinguish when exposed to a butane torch without flame spread or shrinking of the foam. Cone calorimetry showed a peak heat release rate reduction of 66% relative to uncoated foam. Combining these two layer-by-layer systems produces a stacked coating that eliminates melt dripping and reduces the overall flammability of the polyurethane foam, which is commonly used in furniture. This coating acts as an environmentally benign template for flame retarding various complex substrates, especially those found in household furnishings.

Stacking intumescing multilayer thin film onto clay-based nanobrick wall to impart self-extinguishing fire retardant behavior to polyurethane

249th National Meeting (2015)

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