Heat release and structural collapse of flexible polyurethane foam

Porous Microspheres as Pathogen Traps for Sepsis Therapy: Capturing Active Pathogens and Alleviating Inflammatory Reactions

Sepsis is a systemic inflammatory response syndrome caused by pathogen infection, while the current antibiotics mainly utilized in clinical practice to combat infection result in the release of pathogen-associated molecular patterns (PAMPs) in the body. Herein, we provide an innovative strategy for controlling sepsis, namely, capturing active pathogens by means of extracorporeal blood purification. Carbon nanotubes (CNTs) were modified with dimethyldiallylammonium chloride (DDA) through γ-ray irradiation-induced graft polymerization to confer a positive charge. Then, CNT-DDAs are blended with polyurethane (PU) to prepare porous microspheres using the electro-spraying method. The obtained microspheres with a pore diameter of 2 μm served as pathogen traps and are termed as PU-CNT-DDA microspheres. Even at a high flow rate of 50 mL·min-1, the capture efficiencies of the PU-CNT-DDAs for Escherichia coli and Staphylococcus aureus remained 94.7% and 98.8%, respectively. This approach circumvents pathogen lysis and mortality, significantly curtails the release of PAMPs, and hampers the production of pro-inflammatory cytokines. Therefore, hemoperfusion using porous PU-CNT-DDAs as pathogen traps to capture active pathogens and alleviate inflammation opens a new route for sepsis therapy.

Synergistic Combination of Dual Clays in Multilayered Nanocomposites for Enhanced Flame Retardant Properties

In an effort to reduce the flammability of synthetic polymeric materials such as cotton fabrics and polyurethane foam (PUF), hybrid nanocoatings are prepared by layer-by-layer assembly. Multilayered nanocomposites of a cationic polyelectrolyte, poly(diallyldimethylammonium chloride) (PDDA), are paired with two kinds of clay nanoplatelets, montmorillonite (MMT) and vermiculite (VMT). The physical properties such as thickness and mass and thermal behaviors in clay-based nanocoatings with and without incorporation of tris buffer are compared to assess the effectiveness of amine salts on flame retardant (FR) performances. A PDDA-tris/VMT-MMT system, in which tris buffer is introduced into the cationic PDDA aqueous solution, produces a thicker and heavier coating. Three different systems, including PDDA/MMT, PDDA/VMT-MMT, and PDDA-tris/VMT-MMT, result in conformal coating, retaining the weave structure of the fabrics after being exposed to a vertical and horizontal flame test, while the uncoated sample is completely burned out. The synergistic effects of dual clay-based hybrid nanocoatings are greatly improved by adding amine salts. Cone calorimetry reveals that the PDDA-tris/VMT-MMT-coated PUF eliminates a second peak heat release rate and significantly reduces other FR performances, compared to those obtained from the clay-based multilayer films with no amine salts added. Ten bilayers of PDDA-tris/VMT-MMT (≈250 nm thick) maintain the shape of foam after exposure to a butane torch flame for 12 s. As for practical use of these nanocomposites in real fire disasters, spray-assisted PDDA-tris/VMT-MMT multilayers on woods exhibit high resistance over flammability. Improved fire resistance in PDDA-tris/VMT-MMT is believed to be due to the enhanced char yield through the addition of tris buffer that promotes the deposition of more clay particles while retaining a highly ordered deposition of a densely packed nanobrick wall structure. This work demonstrates the ability to impart significant fire resistance to synthetic polymer materials in a fully renewable nanocoating that uses environmentally benign chemistry.

"Floating Catalytic Foam" with prominent heat-induced convection for the effective photocatalytic removal of antibiotics

Immobilized photocatalysts represent a promising candidate for the wastewater treatments due to their good reusability, high stability and low eco-risk. Mass transfer within the immobilized catalytic bed is a crucial process that determines the contacting, adsorption, and degradation kinetics in the photodegradation. In this study, a floating catalytic foam (FCF) with a prominent pumping effect was designed to promote mass transfer. The polyurethane foam immobilized with rGO/TiO2/ultrathin-g-C3N4 photocatalyst (PRTCN) was prepared by a simple dip-coating and Uv-light aging process. It was found that the hydrophilic-hydrophobic interfaces could not only contribute to the floating of the catalyst but also establish a temperature gradient across the floating immobilized catalyst. In addition, the temperature gradient induced convection could serve as a built-in pump to effectively promote the diffusion and adsorption of target antibiotic molecules during the photocatalytic process. Therefore, the PRTCN demonstrated a high photodegradation and mineralization efficiency with excellent reusability and anti-interference capability. Moreover, the photodegradation mechanism and the intermediates' toxicity of norfloxacin were detailly investigated by ultra-high resolution electrospray time-of-flight mass spectrometry, density functional theory simulation and ECOSAR estimation. This work proposed a facile and sustainable strategy to enhance the mass transfer problem on immobilized photocatalysts, which could promote the application of the immobilized photocatalysts in the real water-treatment scenarios.

Analysis of Flammability and Smoke Emission of Plastic Materials Used in Construction and Transport

This study provides valuable data on the specific toxic products that could be released from the commercially used, flexible polyurethane foams (FPUFs) during a fire. The steady-state tube furnace (Purser furnace) was used to generate combustion and thermal degradation products under different fire conditions. The concentrations of asphyxiates and irritant gases were determined using a Fourier transform infrared spectroscopy gas analyser. The volatile and semi-volatile organic compounds released in the fire effluents were collected using the solid-phase microextraction technique and identified by gas chromatography with a mass selective detector. In addition, the thermal stability of the FPUFs was evaluated by simultaneous thermal analysis. The cone calorimetry test was used to determine the flame retardancy of the selected materials. The obtained results show that the emission of carbon monoxide and hydrogen cyanide during the thermal degradation and combustion of the tested foams exceeded the permissible values and pose a serious threat to human life and health. Moreover, substituted benzenes, aldehydes, and polycyclic hydrocarbons were found in the released gases during all of the test conditions.

Flame-Retardant and Smoke-Suppressant Flexible Polyurethane Foams Based on Phosphorus-Containing Polyester Diols and Expandable Graphite

A liquid-phosphorus-containing polyester diol, PPE, was prepared via condensation polymerization using commercial reactive flame retardant 9,10-dihydro-10-[2,3-di(hydroxycarbonyl)propyl]-10-phospha-phenanthrene-10-oxide, adipic acid, ethylene glycol, and 1,4-butanediol. PPE and/or expandable graphite (EG) were then incorporated into phosphorus-containing flame-retardant polyester-based flexible polyurethane foams (P-FPUFs). The structure and properties of the resultant P-FPUFs were characterized using scanning electron microscopy tensile measurements, limiting oxygen index (LOI), vertical burning tests, cone calorimeter tests, thermogravimetric analysis coupled with Fourier-transform infrared spectroscopy, X-ray photoelectron spectroscopy, and Raman spectroscopy. Unlike the FPUF prepared using regular polyester polyol (R-FPUF), PPE increased the flexibility and elongation at break of the resultant forms. More importantly, the peak heat release rate (PHRR) and total heat release (THR) of P-FPUF were reduced by 18.6% and 16.3%, respectively, via gas-phase-dominated flame-retardant mechanisms, compared with those of R-FPUF. The addition of EG further reduced the peak smoke production release (PSR) and total smoke production (TSP) of the resultant FPUFs while increasing the LOI and char formation. Interestingly, it was observed that EG noticeably improved the residual quantity of phosphorus in the char residue. When the EG loading was 15 phr, the resulting FPUF (P-FPUF/15EG) attained a high LOI value (29.2%) and exhibited good anti-dripping performance. Meanwhile, the PHRR, THR, and TSP of P-FPUF/15EG were significantly decreased by 82.7%, 40.3%, and 83.4%, respectively, compared with those of P-FPUF. This superior flame-retardant performance can be attributed to the combination of the bi-phase flame-retardant behavior of PPE and condensed-phase flame-retardant characteristics of EG.

Sustainable wheat gluten foams with self-expansion and water/blood-triggered shape recovery

A cheap and easily obtainable wheat gluten (WG) was used to fabricate bio-foams via a simple method of stirring, heating, and lyophilization. The foam possesses a 3D layered porous structure with interconnected channels, and the biofoam has excellent mechanical properties through glycerol plasticization and glutaraldehyde (GA) cross-linking. The water absorption and volume expansion rate can reach 793.67 ∼ 918.45% and 201.47 ∼ 239.53% respectively. In dry state, the foams had good compression resilience, and can basically recover its original shape after withstanding 60% compression strain for about 7 h. In wet state, they can withstand 10 cycles of compression test, and had good compressive resilience and durability; they also had fast liquid-triggered shape recovery performance, of which the foams can reabsorb liquid, expand, and recover its original shape within 40 seconds after withstanding 80% compression strain. In addition, The hemolysis rates of red blood cells treated with 1, 3, and 5 mg/mL of 14WG-20g-5GA foam suspension were 0.53 ± 0.12%, 2.12 ± 0.34%, and 3.97 ± 0.21%, respectively, all of which were below the permissible range for biological materials (<5%). The above-mentioned advantages made the sustainable foams be potentially useful for medical dressings, especially for the treatment of non-compressible haemorrhaging, which offered a new field of application for WG protein and its added value was also increased obviously.

It Takes Two to Tango: Synergistic Expandable Graphite–Phosphorus Flame Retardant Combinations in Polyurethane Foams

Due to the high flammability and smoke toxicity of polyurethane foams (PUFs) during burning, distinct efficient combinations of flame retardants are demanded to improve the fire safety of PUFs in practical applications. This feature article focuses on one of the most impressive halogen-free combinations in PUFs: expandable graphite (EG) and phosphorus-based flame retardants (P-FRs). The synergistic effect of EG and P-FRs mainly superimposes the two modes of action, charring and maintaining a thermally insulating residue morphology, to bring effective flame retardancy to PUFs. Specific interactions between EG and P-FRs, including the agglutination of the fire residue consisting of expanded-graphite worms, yields an outstanding synergistic effect, making this approach the latest champion to fulfill the demanding requirements for flame-retarded PUFs. Current and future topics such as the increasing use of renewable feedstock are also discussed in this article.

Development and Characterization of Tailored Polyurethane Foams for Shock Absorption

In this paper, different types of polyurethane foams (PUR) having various chemical compositions have been produced with a specific density to monitor the microstructure as much as possible. The foam may have a preferential orientation in the cell structure. The cellular polyurethane tends to have stubborn, typical cellular systems with strong overlap reversibility. Free expansion under atmospheric pressure enables formulas to grow until they are refined. Moreover, the physicochemical characterization of the developed foams was carried out. They later are described by apparent density, Shore hardness, Raman spectroscopy analysis, X-ray diffraction analysis, FTIR, TGA, DSC, and compression tests. The detailed structural characterization was used by scanning electron microscope (SEM) and an optical microscope (MO) to visualize the alveolar polymer’s semi-opened cells, highlighting the opened-cell morphology and chemical irregularities. Polyurethane foams with different structural variables have a spectrum characterization that influences the phase separation and topography of polyurethane foam areas because their bonding capability with hydrogen depends on chain extender nature. These studies may aid in shock absorption production; a methodology of elaboration and characterization of filled polyurethane foams is proposed.

Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming

Megapores with spherical-like cells connected through windows and high porosities make up catalyst supports in the form of ceramic foams. These characteristics provide significant benefits for catalytic processes that are limited by mass or heat transport. This study focuses on the manufacture of ceramic foam using a polymeric sponge replica process and polymer foams as a template for catalyst supports, which are industrial waste from the packaging sector. To make ceramic foam catalysts, they were dipped in a catalyst solution, followed by a breakdown stage and a sintering process. Experiments focused on determinants that affect the desired characteristics of ceramic foams, such as the types of polymer foams that affect foam morphology, the rheology of catalyst solution that affects catalyst dispersion, and the polymer decomposition rate that affects catalytic performance during dry reforming of the methane process. The cell architectures of polyurethane and polyvinyl alcohol foams are attractive for catalyst support preparation because they have 98-99% porosity and typical cell sizes of 200 and 50 μm, respectively. The polyurethane performance was superior to the performance of polyvinyl alcohol in terms of higher porosity and better catalytic-solution absorption offering high catalyst active areas. The catalyst prepared from concentrated 10 wt % Ni/Al₂O₃-MgO (10NAM) slurry had the highest surface area (59.18 m²/g) and the highest metal oxide dispersion (5.65%). These results are relevant to the flow behavior of catalyst slurry which plays a key role in coating the catalyst gel on the polymer template. The thermal decomposition rate used to remove the polymer template from the catalyst structure is proportional to the ceramic foam structure (catalyst support structure). The slow decomposition rate bent and fractured foam-cell struts more than the faster rate. On the other hand, achieving good catalyst dispersion on catalyst supports necessitated a high sintering rate. When sintering was adjusted at a high sintering rate, the metal-particle dispersion was relatively high, around 7.44%, and the surface area of ceramic foam catalysts was 64.61 m²/g. Finally, the catalytic behavior toward hydrogen production through the dry reforming of methane using a fixed-bed reactor was evaluated under certain operating conditions.

Waste Wood Particles from Primary Wood Processing as a Filler of Insulation PUR Foams

A significant part of the work carried out so far in the field of production of biocomposite polyurethane foams (PUR) with the use of various types of lignocellulosic fillers mainly concerns rigid PUR foams with a closed-cell structure. In this work, the possibility of using waste wood particles (WP) from primary wood processing as a filler for PUR foams with open-cell structure was investigated. For this purpose, a wood particle fraction of 0.315–1.25 mm was added to the foam in concentrations of 0, 5, 10, 15 and 20%. The foaming course of the modified PUR foams (PUR-WP) was characterized on the basis of the duration of the process’ successive stages at the maximum foaming temperature. In order to explain the observed phenomena, a cellular structure was characterized using microscopic analysis such as SEM and light microscope. Computed tomography was also applied to determine the distribution of wood particles in PUR-WP materials. It was observed that the addition of WP to the open-cell PUR foam influences the kinetics of the foaming process of the PUR-WP composition and their morphology, density, compressive strength and thermal properties. The performed tests showed that the addition of WP at an the amount of 10% leads to the increase in the PUR foam’s compressive strength by 30% (parallel to foam’s growth direction) and reduce the thermal conductivity coefficient by 10%.

Performance and Failure Mechanism of Fire Barriers in Full-Scale Chair Mock-ups

The effectiveness and the failure mechanism of fire barriers in residential upholstered furniture were investigated by full-scale flaming tests on upholstered chair mock-ups. Six commercial fire barriers were tested in this study. Fire barriers were screened for (1) the presence of elements that are typically used in fire retardants and, (2) the presence of targeted fire retardants. For each fire barrier, triplicate flammability tests were run on chair mock-ups where polyurethane foam and polyester fiber fill were used as the padding materials, and each chair component was fully wrapped with the fire barrier of choice and a polypropylene cover fabric. The ignition source was an 18 kW square propane burner, impinging on the top surface of the seat cushion for 80 s. Results showed all six fire barriers reduced the peak heat release rate (as much as ≈ 64 %) and delayed its occurrence (up to ≈ 19 min) as compared to the control chair mock-ups. The heat release rate remained at a relatively low plateau level until liquid products (generated by either melting or pyrolysis of the padding material) percolated through the fire barrier at the bottom of the seat cushion and ignited, while the fire barrier was presumably intact. The flaming liquid products dripped and quickly formed a pool fire under the chair and the peak heat release rate occurred shortly thereafter. Ultimately, the ignition of the percolating liquid products at the bottom of the seat cushion was identified as the mechanism triggering the failure of the fire barrier.

Viscoelastic Polyurethane Foam with Keratin and Flame-Retardant Additives

Viscoelastic polyurethane (VEPUR) foams with increased thermal resistance are presented in this article. VEPUR foams were manufactured with the use of various types of flame retardant additives and keratin fibers. The structure of the modified foams was determined by spectrophotometric-(FTIR), thermal-(DSC), and thermogravimetric (TGA) analyses as well as by scanning electron microscopy (SEM). We also assessed the fire resistance, hardness, and comfort coefficient (SAG factor). It was found that the use of keratin filler and flame retardant additives changed the foams’ structure and properties as well as their burning behavior. The highest fire resistance was achieved for foams containing keratin and expanding graphite, for which the reduction in heat release rate (HRR) compared to VEPUR foams reached 75%.

Effects of Graphite Oxide Nanoparticle Size on the Functional Properties of Layer-by-Layer Coated Flexible Foams

The exploitation of self-assembled coatings comprising graphite oxide (GO) nanoplates has been recently demonstrated as a promising route to improve the fire safety of flexible polyurethane (PU) foams. However, limited knowledge has been gathered on the correlations between the physical and chemical properties of different GO grades and the performance obtained in this application. This work addresses the effects of the nanoparticle dimensions on the layer-by-layer (LbL) assembly and flame-retardant properties of GO-based coatings deposited on PU foams. To this aim, three GO bearing different lateral sizes and thicknesses were selected and LbL-assembled with chitosan (CHIT). Coating growth and morphology were evaluated by FTIR and FESEM, respectively. The resulting CHIT/GO assemblies were demonstrated to be capable of slowing down the combustion of the PU both in flammability and forced combustion tests. In addition, compressive stress/strain tests pointed out that the LbL-coated foams (22-24 kg/m³) could easily replace denser commercial PU foam (40-50 kg/m³) with weight reduction potentials in the transport field. These results are correlated with the properties of the employed GO. The production of assemblies characterized by a high density of CHIT/GO interfaces is identified as the main parameter controlling the FR efficiency and the mechanical properties of the coatings.

In situ self-foaming preparation of hydrophobic polyurethane foams for oil/water separation

Polyurethane foams with excellent oil–water separation performance were prepared using hydrophobic raw materials with the assistance of a physical cooling agent.

Influence of Density on Foam Collapse under Burning

The fire behaviour of flexible polyurethane foams was studied using a cone calorimeter, with a special emphasis on the collapse step. Only one peak of heat release rate, ranging from 200 to 450 kW/m2, is observed for thin foams, depending on the foam density and the heat flux. On the contrary, heat release rate (HRR) curves exhibit two peaks for 10 cm-thick foams, the second one corresponding to the pool fire formed after foam collapse. In all cases, the collapse occurs at a constant rate through the whole thickness. The rate of the recession of the front was calculated using digital and infrared cameras. Interestingly, its value is relatively constant whatever the heat flux (especially between 25 and 35 kW/m2), probably because of the very low heat conductivity preventing heat transfer through the thickness. The rate increases for the lightest foam but the fraction of burnt polymer during collapse is constant. Therefore, the pool fire is more intense for the densest foam. A simple macroscopic model taking into account only the heat transfer into the foam leads to much lower front recession rates, evidencing that the collapse is piloted by the cell walls' rigidity.

Fire behavior of innovative alginate foams

A new biosourced composite foam (AF, associating foamed alginate matrix and orange peel filler) is successfully tested for fire-retardant properties. This material having similar thermal insulating properties and density than fire-retardant polyurethane foam (FR-PUF, a commercial product) shows promising enhanced properties for flame retardancy, as assessed by different methods such as thermogravimetric analysis (TGA), pyrolysis combustion flow calorimetry (PCFC) and a newly designed apparatus called RAPACES for investigating large-scale samples. All these methods confirm the promising properties of this alternative material in terms of fire protection (pHRR, THR, EHC, time-to-ignition, flame duration or production of residue), especially for heat flux not exceeding 50 kW m^-2. At higher heat flux (i.e., 75 kW m^-2), flame retardant properties tend to decrease but maintain at a higher level than FR-PUF. The investigation of the effect of AF thickness shows that the critical thickness (CT) is close to 1.5-1.7 cm: heat diffusion and material combustion are limited to the CT layer that protects the underlying layers from combustion. A multiplicity of factors can explain this behavior, such as: (a) negligible heat conduction, (b) low heat of combustion, (c) charring formation, and (d) water release. Water being released from underlying layers, dilutes the gases emitted during the combustion of superficial layers and promotes the flame extinction.

Environmentally Benign and Self-Extinguishing Multilayer Nanocoating for Protection of Flammable Foam

Most current flame-retardant nanocoatings for flexible polyurethane foam (PUF) consist of passive barriers, such as clay, graphene oxide, or metal hydroxide. In an effort to develop a polymeric and environmentally benign nanocoating for PUF, positively charged chitosan (CH) and anionic sodium hexametaphosphate (PSP) were deposited using layer-by-layer (LbL) assembly. Only six bilayers of CH/PSP film can withstand flame penetration during exposure to a butane torch (∼1400 °C) for 10 s and stop flame spread on the foam. Additionally, cone calorimetry reveals that the fire growth rate, peak heat release rate, and maximum average rate of heat emission are reduced by 55, 43, and 38%, respectively, compared with uncoated foam. This multilayer thin film quickly dehydrates to form an intumescent charred exoskeleton on the surface of the open-celled structure of polyurethane, inhibiting heat transfer and completely eliminating melt dripping. This entirely polymeric nanocoating provides a safe and effective alternative for reducing the fire hazard of polyurethane foam that is widely used for cushioning and insulation.

Nacre-Mimetic Green Flame Retardant: Ultra-High Nanofiller Content, Thin Nanocomposite as an Effective Flame Retardant

A nacre-mimetic brick-and-mortar structure was used to develop a new flame-retardant technology. A second biomimetic approach was utilized to develop a non-flammable elastomeric benzoxazine for use as a polymer matrix that effectively adheres to the hydrophilic laponite nanofiller. A combination of laponite and benzoxazine is used to apply an ultra-high nanofiller content, thin nanocomposite coating on a polyurethane foam. The technology used is made environmentally friendly by eliminating the need to add any undesirable flame retardants, such as phosphorus additives or halogenated compounds. The very-thin coating on the polyurethane foam (PUF) is obtained through a single dip-coating. The structure of the polymer has been confirmed by proton nuclear magnetic resonance spectroscopy (1H NMR) and Fourier transform infrared spectroscopy (FTIR). The flammability of the polymer and nanocomposite was evaluated by heat release capacity using microscale combustion calorimetry (MCC). A material with heat release capacity (HRC) lower than 100 J/Kg is considered non-ignitable. The nanocomposite developed exhibits HRC of 22 J/Kg, which is well within the classification of a non-ignitable material. The cone calorimeter test was also used to investigate the flame retardancy of the nanocomposite's thin film on polyurethane foam. This test confirms that the second peak of the heat release rate (HRR) decreased 62% or completely disappeared for the coated PUF with different loadings. Compression tests show an increase in the modulus of the PUF by 88% for the 4 wt% coating concentration. Upon repeated modulus tests, the rigidity decreases, approaching the modulus of the uncoated PUF. However, the effect of this repeated mechanical loading does not significantly affect the flame retarding performance.

Synthesis and Properties of Moisture-Cured Reactive Polyurethane Containing Castor Oil and Oxime Compounds

Reactive polyurethane hot-melt resin (moisture-cured reactive polyurethane, PUR) could successfully be prepared from poly(tetramethylene ether) glycol (PTMG), castor oil and dimethylglyoxime (DMG) by one or two-stage synthesis. Fourier-transform infrared spectroscopy (FTIR) analysis showed that the synthesis resins belonged to NCO-capped castor oil-based polyurethane. The thermal behaviors of the cured PUR were analyzed by differential scanning calorimeter (DSC) and dynamic mechanical analyzer (DMA) instruments. The results showed that the cured resin provided remeltable properties under the dosages of 3 wt% DMG. Furthermore, the phenomenon could be proved by FTIR analysis according to the characteristic absorption peak of NCO groups after the cured resin was heated. Comparing different syntheses, the resin prepared by one-stage synthesis showed random distribution of DMG with PUR structure and that prepared by two-stage synthesis had distribution of DMG with branching structure in the prepolymer. The former obtained lower remeltable temperatures from 90 to 130 °C than the latter temperatures, which had temperatures above 125 °C. The tensile test showed that all of the PUR films exhibited typical tough behavior. Thus, the cured resin with DMG dosages of 3 wt% provided remeltable and mechanical properties at the same time. Overall, the crosslinking density and numbers of dynamic bonds should be kept in balance for preparation of remeltable PUR.

Titania-Coated Alumina Foam Photocatalyst for Memantine Degradation Derived by Replica Method and Sol-Gel Reaction

In the present work, alumina (Al₂O₃) foam was prepared by the replica method where a polyurethane (PU) foam (30 pores per inch (ppi)) template was impregnated with a 60 wt.% Al₂O₃ suspension. Sintered Al₂O₃ foam was used as substrate for the deposition of sol-gel derived titania (TiO₂) film using dip coating. For the preparation of TiO₂ sol, titanium(IV) isopropoxide (Ti-iPrOH) was used as the precursor. The common problem of qualification and quantification of a crystalline coating on a highly porous 3D substrate with an uneven surface was addressed using a combination of different structural characterization methods. Using Powder X-ray Diffraction (PXRD) and synchrotron Grazing Incidence X-ray Diffraction (GIXRD) on bulk and powdered Al₂O₃ foam and TiO₂-coated Al₂O₃ foam samples, it was determined Al₂O₃ foam crystallizes to corundum and coating to anatase, which was also confirmed by Fourier Transformed Infrared Spectroscopy (FTIR). Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy (SEM/EDS) revealed the structural and microstructural properties of the substrate and coating. Differential Thermal Analysis (DTA) and Thermogravimetric Analysis (TGA) were used to clarify the evolution of the porous microstructure. The Al₂O₃-TiO₂ composite was evaluated as a photocatalyst candidate for the degradation of the micropollutant medication memantine. The degradation rate was monitored using a light-emitting diode (LED) lamp operating at electromagnetic (EM) wavelength of 365 nm. The photocatalytic activity of sol-gel-derived TiO₂ film immobilized on the Al₂O₃ foam was compared with commercially available TiO₂ nanoparticles, P25-Degussa, in the form of a suspension. The levels of memantine were monitored by High-Performance Liquid Chromatography–Tandem Mass Spectrometry (HPLC–MS/MS). The efficiency and rate of the memantine photodegradation by suspended TiO₂ nanoparticles is higher than the TiO₂-coated Al₂O₃ foam. But, from the practical point of view, TiO₂-coated Al₂O₃ foam is more appropriate as a valuable photocatalytic composite material.

Influences of surface material on the fire behaviors of two-layer combustibles under autoignition conditions

Upholstered furniture usually has a typical two-layer structure with an ultra-thin surface layer. The surface layer can significantly affect the overall fire behaviors of the upholstered furniture. A series of experiments were carried out to investigate the fire behaviors of six two-layer combustibles based on a cone calorimeter. An empirical model was proposed to predict the heat release rate of two-layer combustibles. The predictions of the model are fitting quite well with experimental data. It was also known that the ignition time of the two-layer combustis dbles is controlled by those surface fabric materials. The shrink rate and the properties of the residues of those surface fabrics show obvious influences on the combustion processes. Comparing to those uncovered natural latex foam samples, it was known that the peak heat release rate decreases about 26.9% and 11.7% for the samples with natural and synthetic species covers, respectively; and the duration of the burning process increases about 41.7% and 15.4%, respectively. A combustion factor was proposed and a heat transfer model was developed to reflect the contribution of the surface and the second layers to the combustion processes. The combustion factor is within 0.7-0.9 for the six types of surface fabrics.

Combustion behaviour and dominant shrinkage mechanism of flexible polyurethane foam in the cone calorimeter test

The shrinkage is an important thermal response of flexible polyurethane foam (FPUF) in fire, which couples its first combustion stage and influences the initial fire spread. In this paper the combustion and shrinkage behaviours are quantitatively investigated and the shrinkage mechanisms are discussed. The critical heat flux for the shrinkage is about 13 kW/m², between the critical heat flux for piloted ignition and that for non-piloted ignition. Above the critical value the shrinkage rate increases linearly with increasing the heat flux. As the foam density decreases both the shrinkage rate and the first peak of Figra curve which reflects the initial fire spread rate increase. The perceptible shrinkage originates from the decomposition via which the struts convert to the melts. Both the shrinking of struts and the gasification play a minor role. The collapse of porous structure, namely the melts filling into the pores to form the tar layer, dominates the shrinkage. The tar is composed of polyols produced after the first decomposition stage. Beneath the tar layer the porous structure is unchanged. To reduce the fire hazards of FPUF by its heat insulation merit it needs to maintain the porous structure at the first decomposition stage.

Fire Phenomena of Rigid Polyurethane Foams

Rigid polyurethane foams (RPUFs) typically exhibit low thermal inertia, resulting in short ignition times and rapid flame spread. In this study, the fire phenomena of RPUFs were investigated using a multi-methodological approach to gain detailed insight into the fire behaviour of pentane- and water-blown polyurethane (PUR) as well as pentane-blown polyisocyanurate polyurethane (PIR) foams with densities ranging from 30 to 100 kg/m³. Thermophysical properties were studied using thermogravimetry (TG); flammability and fire behaviour were investigated by means of the limiting oxygen index (LOI) and a cone calorimeter. Temperature development in burning cone calorimeter specimens was monitored with thermocouples inside the foam samples and visual investigation of quenched specimens’ cross sections gave insight into the morphological changes during burning. A comprehensive investigation is presented, illuminating the processes taking place during foam combustion. Cone calorimeter tests revealed that in-depth absorption of radiation is a significant factor in estimating the time to ignition. Cross sections examined with an electron scanning microscope (SEM) revealed a pyrolysis front with an intact foam structure underneath, and temperature measurement inside burning specimens indicated that, as foam density increased, their burning behaviour shifted towards that of solid materials. The superior fire performance of PIR foams was found to be based on the cellular structure, which is retained in the residue to some extent.

Thermal conductivity and flammability of multiwall carbon nanotube/polyurethane foam composites

The thermal conductivity and fire response of multiwall carbon nanotube/polyurethane foam composites are investigated for ∼45 kg/m3 foams with multiwall carbon nanotube concentrations of 0.1, 1, and 2 wt.%. The thermal conductivity of such nanocomposites shows a modest increase with increased multiwall carbon nanotube content, which is explained by a high value of interfacial thermal resistance, as predicted by existent thermal models. A strong correlation between multiwall carbon nanotube content, foam’s cellular morphology, and fire behavior was observed. The flame propagation speed increases with the addition of 0.1 wt.% multiwall carbon nanotubes and then reduces as the multiwall carbon nanotube content increases. The mass lost after flame extinction reduces with the addition of multiwall carbon nanotubes, suggesting an increased resistance to flame attack due the multiwall carbon nanotube presence.

Fire retardant sol–gel coatings for flexible polyurethane foams

Untreated flexible polyurethane foams used in upholstered products are prone to rapid fire growth. Sol–gel process was evaluated to flame retard it. A successful intumescent formulation gave 60% reduction of the peak of heat release rate.

Comparative study of layer by layer assembled multilayer films based on graphene oxide and reduced graphene oxide on flexible polyurethane foam: flame retardant and smoke suppression properties

Flame retardant multilayer films based on graphene materials were deposited on the surface of flexible polyurethane (FPU) foam by an advanced layer by layer assembly method (hybrid bilayer approach) in an effort to reduce its flammability.