Efficient and economical synthesis of flame retardant rigid polyurethane nanocomposite foam through phosphorus-based compounds and in-situ exfoliated microcrystal muscovite

ABSTRACT

A flame retardant rigid polyurethane foam (FR-RPUF) boasting good mechanical properties is developed by integrating phosphorus-based compounds (DBHP/DMMP) and organically modified microcrystal muscovite (OM-MCM). During foaming, OM-MCM undergoes in-situ exfoliation, yielding RPUF nanocomposites with heightened mechanical strength. The combined deployment of OM-MCM and DBHP/DMMP enables FR-RPUF to achieve an excellent flame retardancy (such as UL94 V-0 rating). This flame retardant effect stems from a bi-phase mechanism: trapping effect of phosphorus-containing radicals in the gas phase and enhanced charring of nanominerals in the condensed phase. Overall, this accessible method enhances flame resistance in RPUF using conventional processes and available materials.

GRAPHICAL ABSTRACT

KEYWORDS:

• Flame retardant
• microcrystalline muscovite
• nanocomposite
• rigid polyurethane foam

Acknowledgments

This work was supported by the Environmental Science and Technology Company Limited, No.1 Bureau of CMGB (grant numbers: CMGB7934732).

Disclosure statement

No potential conflict of interest was reported by the author(s).

Supplementary material

Supplemental data for this article can be accessed online at https://doi.org/10.1080/25740881.2023.2289063

Additional information

Funding

The work was supported by the Comprehensive development and utilization of mineral resources [CMGB7934732].

Notes on contributors

Weiqing Zheng

Weiqing Zheng, a senior engineer employed at Environmental Science and Technology Company Limited, No.1 Bureau of CMGB, specializing in the comprehensive utilization and development of mineral resources.

Junguo Du

Junguo Du, an engineer at Environmental Science and Technology Company Limited, No.1 Bureau of CMGB, involved in the comprehensive utilization and development of mineral resources.

Zhen Wu

Zhen Wu, a senior engineer at Environmental Science and Technology Company Limited, No.1 Bureau of CMGB, engaged in the comprehensive utilization and development of mineral resources.

Minghui Yin

Minghui Yin, holds a Ph.D. from Chengdu University of Technology and currently serves as a lecturer at the School of Resource and Environmental Engineering, Mianyang Teachers’ College, focusing on the development of mineral resources.

Wei Liu

Wei Liu, a senior engineer at Environmental Science and Technology Company Limited, No.1 Bureau of CMGB, specializing in research on high polymer composites. Shihu Han: Currently pursuing a Ph.D. at Southwest University of Science and Technology, conducting research in the field of polymer flame retardancy.

Shihu Han

Shihu Han, currently pursuing a Ph.D. at Southwest University of Science and Technology, conducting research in the field of polymer flame retardancy.