Thermal degradation of polyurethane and polyurethane/expandable graphite coatings

Cage Nanofillers' Influence on Fire Hazard and Toxic Gases Emitted during Thermal Decomposition of Polyurethane Foam

Polyurethane (PUR), as an engineering polymer, is widely used in many sectors of industries. However, the high fire risks associated with PUR, including the smoke density, a high heat release rate, and the toxicity of combustion products limit its applications in many fields. This paper presents the influence of silsesquioxane fillers, alone and in a synergistic system with halogen-free flame-retardant compounds, on reducing the fire hazard of polyurethane foams. The flammability of PUR composites was determined with the use of a pyrolysis combustion flow calorimeter (PCFC) and a cone calorimeter. The flammability results were supplemented with smoke emission values obtained with the use of a smoke density chamber (SDC) and toxicometric indexes. Toxicometric indexes were determined with the use of an innovative method consisting of a thermo-balance connected to a gas analyzer with the use of a heated transfer line. The obtained test results clearly indicate that the used silsesquioxane compounds, especially in combination with organic phosphorus compounds, reduced the fire risk, as expressed by parameters such as the maximum heat release rate (HRRmax), the total heat release rate (THR), and the maximum smoke density (SDmax). The flame-retardant non-halogen system also reduced the amounts of toxic gases emitted during the decomposition of PUR, especially NOx, HCN, NH3, CO and CO2. According to the literature review, complex studies on the fire hazard of a system of POSS-phosphorus compounds in the PUR matrix have not been published yet. This article presents the complex results of studies, indicating that the POSS-phosphorous compound system can be treated as an alternative to toxic halogen flame-retardant compounds in order to decrease the fire hazard of PUR foam.

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.

Understanding the Influence of Gypsum upon a Hybrid Flame Retardant Coating on Expanded Polystyrene Beads

A low-cost and effective flame retarding expanded polystyrene (EPS) foam was prepared herein by using a hybrid flame retardant (HFR) system, and the influence of gypsum was studied. The surface morphology and flame retardant properties of the synthesized flame retardant EPS were characterized using scanning electron microscopy (SEM) and cone calorimetry testing (CCT). The SEM micrographs revealed the uniform coating of the gypsum-based HFR on the EPS microspheres. The CCT and thermal conductivity study demonstrated that the incorporation of gypsum greatly decreases the peak heat release rate (PHRR) and total heat release (THR) of the flame retarding EPS samples with acceptable thermal insulation performance. The EPS/HFR with a uniform coating and the optimum amount of gypsum provides excellent flame retardant performance, with a THR of 8 MJ/m2, a PHRR of 53.1 kW/m2, and a fire growth rate (FIGRA) of 1682.95 W/m2s. However, an excessive amount of gypsum weakens the flame retardant performance. The CCT results demonstrate that a moderate gypsum content in the EPS/HFR sample provides appropriate flame retarding properties to meet the fire safety standards.

A review of blasting waste generation and management in the ship repair industry

Solid blasting waste generated from coating removal during ship repair and maintenance poses environmental challenges. This paper presents a review of the generation, characterization, and treatment of blasting waste in the ship repair industry. The quantities, properties, and environmental impacts of the generated blasting waste are summarized and analyzed, and the results indicate that blasting waste has a high generation rate and/or high toxicity. As alternatives to landfill, available blasting waste treatment methods include hydrometallurgical leaching, physical/physicochemical separation, thermal treatment, and direct utilization in the production of building materials. The advantages and disadvantages of these treatments are reviewed and compared. The production of building materials from blasting waste is currently attractive owning to its economic benefits and technical simplicity, whereas recycling blasting waste for high-value applications is gradually gaining research interest. The high dependence of the choice and performance of treatment methods on the waste type and characteristics is highlighted. The results emphasize the interest in conducting more research on physiochemical and thermal properties and the environmental effects of blasting waste. This review suggests that future research should focus more on paint waste management because of the restricted application of dry abrasive blasting and the development of nonabrasive blasting methods in the ship repair industry.

Hazard evaluation of indoor environment based on long-term pollutant emission characteristics of building insulation materials: An empirical study

Insulation materials are essential components in construction, and their main objective is to increase the efficiency of thermal energy by minimizing internal and external thermal exchange. Accordingly, research and development studies are being actively conducted to increase the thermal resistance of insulation materials, and high-performance insulation materials that use organic chemicals have been developed after industrialization. However, thermal insulation comprising chemicals poses a potential risk of pollutant emissions and can cause health problems. In this study, five types of insulation materials and the contaminants generated from the building materials used in insulation construction were quantitatively analyzed. In addition, an empirical study on the discharge of pollutants was conducted using a test bed, and the effects of the pollutants discharged from the insulation material on the indoor environment were examined by analyzing the pollutant concentration for 90 days. In addition, we analyzed the effect of an insulation material on an indoor environment through the standard specifications. Moreover, the necessity of legal management of the emission of contaminants from insulation materials was proposed based on the empirical research results.

Effects of Expanded Graphite, Aluminum Hydroxide, and Kaolin on Flame Retardancy and Smoke Suppression of Polyurethane Composites

Polyurethane is a widely used polymer that has good abrasion resistance and low-temperature resistance. However, polyurethane composite materials are highly inflammable and thus require the use of flame retardants. This study selected green and environment-friendly flame retardants such as expanded graphite, aluminum hydroxide, and kaolin to be used as individual or paired retardants to produce polyurethane composites. By analyzing the potential and mechanical properties of the polyurethane composites, it was found that the composite material with the flame retardant composed of graphite and modified kaolin had better flame retardancy, smoke suppression performance, and high thermal stability.

Fire-retardant wood coating based on natural rubber bearing methacrylic functionality

The main objective of the present work was to develop intumescent fire-retardant coating (IFRC) for wood based on modified natural rubber (NR). A newly modified form of NR, namely graft copolymers of NR and poly(methacrylic acid) (PMAA), NR-g-PMAA, was first synthesized by a solution polymerization technique. The IFRC was then prepared by compounding the synthesized NR-g-PMAA with a curing agent and an intumescent additive to form a compound coating. Cross-linking of the NR-g-PMAA coating was achieved by reactions with polyisocyanate based on hexamethylene diisocyanate (poly‐HDI) under ambient conditions. Interactions of NR-g-PMAA with poly‐HDI were also studied using X-ray photoelectron spectroscopy. Expandable graphite (EG) was employed as intumescent filler in the present study. The thermal stability of the NR-g-PMAA coating films was first studied by thermogravimetric analysis. The fire-retardant properties of wood, with or without the NR-g-PMAA coating, were then examined using the limiting oxygen index and cone calorimetry test. The flammability tests indicate that the flame-retardant properties of wood were greatly improved by treatment with the NR-g-PMAA-based IFRC. Hence, it can be stated that this new form of modified NR has shown to possess potential application in the IFRC when used in combination with EG.

Tailoring synthetic polymeric biomaterials towards nerve tissue engineering: a review

The nervous system is known as a crucial part of the body and derangement in this system can cause potentially lethal consequences or serious side effects. Unfortunately, the nervous system is unable to rehabilitate damaged regions following seriously debilitating disorders such as stroke, spinal cord injury and brain trauma which, in turn, lead to the reduction of quality of life for the patient. Major challenges in restoring the damaged nervous system are low regenerative capacity and the complexity of physiology system. Synthetic polymeric biomaterials with outstanding properties such as excellent biocompatibility and non-immunogenicity find a wide range of applications in biomedical fields especially neural implants and nerve tissue engineering scaffolds. Despite these advancements, tailoring polymeric biomaterials for design of a desired scaffold is fundamental issue that needs tremendous attention to promote the therapeutic benefits and minimize adverse effects. This review aims to (i) describe the nervous system and related injuries. Then, (ii) nerve tissue engineering strategies are discussed and (iii) physiochemical properties of synthetic polymeric biomaterials systematically highlighted. Moreover, tailoring synthetic polymeric biomaterials for nerve tissue engineering is reviewed.

Influence of the Characteristics of Expandable Graphite on the Morphology, Thermal Properties, Fire Behaviour and Compression Performance of a Rigid Polyurethane Foam

Three types of expandable graphite (EG) differing in particle size and expansion volume, are compared as flame retardant additives to rigid polyurethane foams (RPUFs). In this paper we discuss microstructure, thermal stability, fire behavior, and compression performance. We find that ell size distributions were less homogeneous and cell size was reduced. Furthermore, thermal conductivity increased along with EG loading. Thermogravimetric analysis (TGA) showed that EG only increased residue yield differently. The results indicate that a higher expansion of EG increased the limiting oxygen index (LOI) value, whereas a bigger particle size EG improved the rating of the vertical burning test (UL94). Results from the cone calorimeter test showed that a bigger particle size EG effectively reduced peak of heat release rate (pHRR). Furthermore, a higher expansion, led to a decrease in smoke production (TSP). The combination of both characteristics gives extraordinary results. The physical–mechanical characterization of the EG/RPUF foams revealed that their compression performance decreased slightly, mostly due to the effect of a bigger size EG.

Flame-retardant and smoke-suppressant flexible polyurethane foams based on reactive phosphorus-containing polyol and expandable graphite

In this manuscript, flame-retardant and smoke-suppressant flexible polyurethane foams (FPUFs) were designed and synthesized based on novel liquid phosphorus-containing polyol named as PDEO and expandable graphite (EG). The reactive PDEO can be chemically added into the chain of FPUF, while expandable graphite was blended into the matrix of foam through foaming process. Benefitting from the incorporation of reactive PDEO with a long chain, the resultant FPUF containing EG exhibited considerable mechanical properties. More importantly, the synergistic effect of PDEO and EG can endow FPUF with great flame retardancy, anti-driping performances. Furthermore, the resultant FPUF/EG/PDEO foams exhibit considerable smoke suppression performances. The vertical burning test revealed that the FPUF containing 5 php PDEO and 10 php EG extinguished quickly without dripping and kept the original shape after removing the igniter. The cone calorimeter results demonstrated that the synergistic effect of PDEO and EG can effectively reduce the heat release rate (HRR) and total release rate (THR) of the composite foam. Remarkably, the smoke production release (SPR), total smoke production (TSP), light transmission and specific optical density results indicated significantly smoke-suppressant properties of the composite foam. The mechanism analysis confirmed that the synergistic effect of gas-condensed bi-phase action from PDEO and EG contributed the great flame retardation of the composite foam. This novel FPUF provides a promising strategy for producing the polymer foam with flame retardation, smoke suppression and anti-dripping performances.

Cyclodextrin-Grafted TiO₂ Nanoparticles: Synthesis, Complexation Capacity, and Dispersion in Polymeric Matrices

The modification of the surface of titanium dioxide nanoparticles (TiO₂ NPs) by the incorporation of cyclodextrins (CDs), cyclic oligosaccharides with a hydrophobic cavity, can largely improve the functionality of TiO₂ by lodging molecules of interest in the CD to act directly on the surface of the nanoparticles or for further release. With this aim, we have synthesized βCD-modified nanoparticles (βCDTiO₂ NPs) by a two-step reaction that involves the incorporation of a spacer and then the linking of the macrocycle, and characterized them by thermogravimetric analysis (TGA), Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy (SEM). The capacity of the functionalized structures to trap model compounds (Rhodamine and 1-naphthol) has been compared to that of bare TiO₂ NPs by fluorescence and Ultraviolet-visible (UV-visible) spectroscopy. The presence of the CDs on the surface of the TiO₂ avoids the photo-degradation of the guest, which is of interest in order to combine the photocatalytic activity of TiO₂, one of its most interesting features for practical purposes, with the delivery of compounds susceptible of being photo-degraded. The βCDTiO₂ NPs have been dispersed in polymeric matrices of frequently used polymers, polyethylene (LDPE) and polyethylene oxide (PEO), by cryogenic high energy ball milling to produce nanocomposites in the form of films. The surface modification of the nanoparticles favors the homogenization of the filler in the matrix, while the nanoparticles, either in bare or functionalized form, do not seem to alter the crystallization properties of the polymer at least up to a 5% (w/w) load of filler.

Synthesis and Characterization of Highly Intercalated Graphite Bisulfate

Different chemical formulations for the synthesis of highly intercalated graphite bisulfate have been tested. In particular, nitric acid, potassium nitrate, potassium dichromate, potassium permanganate, sodium periodate, sodium chlorate, and hydrogen peroxide have been used in this synthesis scheme as the auxiliary reagent (oxidizing agent). In order to evaluate the presence of delamination, and pre-expansion phenomena, and the achieved intercalation degree in the prepared samples, the obtained graphite intercalation compounds have been characterized by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), X-ray powder diffraction (XRD), infrared spectroscopy (FT-IR), micro-Raman spectroscopy (μ-RS), and thermal analysis (TGA). Delamination and pre-expansion phenomena were observed only for nitric acid, sodium chlorate, and hydrogen peroxide, while the presence of strong oxidizers (KMnO₄, K₂Cr₂O₇) led to stable graphite intercalation compounds. The largest content of intercalated bisulfate is achieved in the intercalated compounds obtained from NaIO₄ and NaClO₃.

Polylactic acid biocomposites: approaches to a completely green flame retarded polymer

Basic paths towards fully green flame retarded kenaf fiber reinforced polylactic acid (K-PLA) biocomposites are compared. Multicomponent flame retardant systems are investigated using an amount of 20 wt% such as Mg(OH)2 (MH), ammonium polyphosphate (APP) and expandable graphite (EG), and combinations with silicon dioxide or layered silicate (LS) nanofillers. Adding kenaf fibers and flame retardants increases the E modulus up to a factor 2, although no compatibilizer was used at all. Thus, in particular adding EG and MH decreases the strength at maximum elongation, and kenaf fibers, MH, and EG are crucial for reducing the elongation to break. The oxygen index is improved by up to 33 vol% compared to 17 vol% for K-PLA. The HB classification of K-PLA in the UL 94 test is outperformed. All flame retarded biocomposites show somewhat lower thermal stability and increased amounts of residue. MH decreases the fire load significantly, and the greatest reduction in peak heat release rate is obtained for K-PLA/15MH/5LS. Synergistic effects are observed between EG and APP (ratio 2:1) in flammability and fire properties. Synergistic multicomponent systems containing EG and APP, or MH with adjuvants offer a promising route to green flame retarded natural fiber reinforced PLA biocomposites.

Study of different-sized sulfur-free expandable graphite on morphology and properties of water-blown semi-rigid polyurethane foams

In this paper, EG with different nominal particle sizes (70 μm, 430 μm and 960 μm) and different loadings from 0 to 50 pphp were considered to investigate the effect of expandable graphite on the morphology and properties of water-blown semi-rigid polyurethane foams (SPFs).

Preparation and properties of flame retardant rigid polyurethane foam with phosphorus–nitrogen intumescent flame retardant

Ethanolamine spirocyclic pentaerythritol bisphosphonate (EMSPB), a novel intumescent flame retardant, was synthesized and used to improve the flame retardancy of rigid polyurethane foam (RPUF). The effects of EMSPB on the flammability, thermal stability, and mechanical properties of RPUF were discussed, respectively. Scanning electron microscopy (SEM) and compression strength tests showed that the EMSPB had favorable compatibility with the RPUF matrix and did not deteriorate the mechanical properties of the RPUF. Flammability of RPUF systems containing various contents of EMSPB was investigated by vertical burning test (UL-94) and limiting oxygen index (LOI) test. Results indicated that when the content of EMSPB was 25 wt%, the LOI of flame retardant RPUF could reach 27.5%, and a UL-94 V-0 rating was achieved. Thermogravimetric analysis showed that RPUF-containing EMSPB had a high yield of residual char at high temperatures, indicating that EMSPB was an effective charring agent. From the SEM observations of the residues of the flame retardant systems burned, the compact charred layers could be seen, which form protective shields to protect effectively the internal structure and inhibited the transmission of heat and heat diffusion during contacting fire.