Very high nanofiller content nanocomposite coating that consists of casein as a naturally abundant polymer matrix and non-exfoliated and/or non-intercalated laponite as an inorganic nanofiller reinforcement has been studied as an effective flame retardant for polyurethane form. The ultra-thin coating is applied via single-dip method. Successful nanocomposite making is confirmed by Fourier transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), and scanning electron microscopy (SEM). Coated PUFs with high laponite concentration in coating shows desirable flammability reduction. With 90wt% laponite concentration, heat release rate (HRR) of the second peak, average heat release rate (aHRR), and total smoke production (TSP) are reduced by 57.0 %, 30.9 %, and 33.3%, respectively, as determined by cone calorimetric experiment. The barrier effect provided by casein/ laponite coating is discussed as the major flame retardant mechanism. Negatively charged clay exfoliated by water-soluble cationic benzoxazine, which is obtained through methylation of tertiary nitrogen atoms is also anticipated to extend the flame routine and elapsed time. This work demonstrates a simple, commercially applicable, and environmentally benign method for flame retardancy.

Towards higher flame retardancy: Very high nanofiller-content nanocomposite single-dip coating for polyurethane foam

254th National Meeting (2017)

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