Optimisation of Additives to Maximise Performance of Expandable Graphite-Based Intumescent-Flame-Retardant Polyurethane Composites

Imrana I. Kabir; Juan Carlos Baena; Wei Wang; Cheng Wang; Susan Oliver; Muhammad Tariq Nazir; Arslan Khalid; Yifeng Fu; Anthony Chun Yin Yuen; Guan Heng Yeoh

doi:10.3390/molecules28135100

Molecules (Jun 2023)

Optimisation of Additives to Maximise Performance of Expandable Graphite-Based Intumescent-Flame-Retardant Polyurethane Composites

Imrana I. Kabir,
Juan Carlos Baena,
Wei Wang,
Cheng Wang,
Susan Oliver,
Muhammad Tariq Nazir,
Arslan Khalid,
Yifeng Fu,
Anthony Chun Yin Yuen,
Guan Heng Yeoh

Affiliations

Imrana I. Kabir: School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW 2052, Australia
Juan Carlos Baena: School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW 2052, Australia
Wei Wang: School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW 2052, Australia
Cheng Wang: School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW 2052, Australia
Susan Oliver: School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW 2052, Australia
Muhammad Tariq Nazir: Electrical and Biomedical Engineering, School of Engineering, RMIT University, Melbourne, VIC 3001, Australia
Arslan Khalid: School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW 2052, Australia
Yifeng Fu: School of Automotive and Traffic Engineering, Jiangsu University, Zhenjiang 212013, China
Anthony Chun Yin Yuen: School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW 2052, Australia
Guan Heng Yeoh: School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW 2052, Australia

DOI: https://doi.org/10.3390/molecules28135100
Journal volume & issue: Vol. 28, no. 13
p. 5100

Abstract

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The effect of varying the weight percentage composition (wt.%) of low-cost expandable graphite (EG), ammonium polyphosphate (APP), fibreglass (FG), and vermiculite (VMT) in polyurethane (PU) polymer was studied using a traditional intumescent flame retardant (IFR) system. The synergistic effect between EG, APP, FG, and VMT on the flame retardant properties of the PU composites was investigated using SEM, TGA, tensile strength tests, and cone calorimetry. The IFR that contained PU composites with 40 wt.% EG displayed superior flame retardant performance compared with the composites containing only 20 w.t.% or 10 w.t.% EG. The peak heat release rate, total smoke release, and carbon dioxide production from the 40 wt.% EG sample along with APP, FG, and VMT in the PU composite were 88%, 93%, and 92% less than the PU control sample, respectively. As a result, the synergistic effect was greatly influenced by the compactness of the united protective layer. The PU composite suppressed smoke emission and inhibited air penetrating the composite, thus reducing reactions with the gas volatiles of the material. SEM images and TGA results provided positive evidence for the combustion tests. Further, the mechanical properties of PU composites were also investigated. As expected, compared with control PU, the addition of flame-retardant additives decreased the tensile strength, but this was ameliorated with the addition of FG. These new PU composite materials provide a promising strategy for producing polymer composites with flame retardation and smoke suppression for construction materials.

Published in Molecules

ISSN: 1420-3049 (Online)
Publisher: MDPI AG
Country of publisher: Switzerland
LCC subjects: Science: Chemistry: Organic chemistry
Website: http://www.mdpi.com/journal/molecules

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