Construction of organic-inorganic hybrid nano-coatings containing α-zirconium phosphate with high efficiency for reducing fire hazards of flexible polyurethane foam

Nano-architecture on the flexible polyurethane foam (FPUF) was built by layer by layer (LbL) self-assembling of α-zirconium phosphate (α-ZrP) and two biopolymers. Through electrostatic attraction and hydrogen bonding between α-ZrP, chitosan and alginate, the nano-coatings were successfully deposited on the substrate. The LbL self-assembly coatings were characterized by X-ray diffraction, UV-vis absorption spectroscopy, attenuated total reflection Fourier transform infrared spectroscopy and scanning electron microscopy. This loaded nano-coating endowed FPUF with excellent flame retardancy. Compared with pure FPUF, the reduction in the peak heat release rate of the modified foam with 12.3 wt% weight gain was achieved 71%, and the melt-dripping during combustion disappeared. Meanwhile, the thermal degradation of coated FPUF under nitrogen atmosphere was obviously retarded compared with pure FPUF. Additionally, the mechanical properties of the treated FPUFs were investigated. After loaded with 12.3 wt% nano-coating, the tensile and tear strength were enhanced by 13% and 54%, respectively. These investigations indicated that the study has great potential to add new dimensions in the fire retardancy modification of FPUF.