Fire-Resistant Flexible Polyurethane Foams via Nature-Inspired Chitosan-Expandable Graphite Coatings

The current methods used to impart flame-retardant or fire-resistant properties to flexible polyurethane foams (PUFs) to meet fire safety requirements entail the use of halogenated phosphorus-based compounds. Whereas these are highly effective as flame retardants, the associated toxicity derived from halogens in the burning fumes are deadly. To address this problem, we herein present a facile and efficient method of fabricating highly fire-resistant flexible PUF using halogen-free nature-inspired coatings. All of the active ingredients used to fabricate the coatings originated from natural or widely available sources: chitosan from crustacean shells, acetic acid that is found in vinegar, and expandable graphite mined from mineral rocks, thus making this strategy environmentally friendly and sustainable. These coatings offer excellent flame-retardant properties; with a limiting oxygen index (LOI) value as high as 31%, the coated foam could potentially pass the highest levels within the British Standard 5852, which is a commonly accepted global industry standard for meeting the fire safety requirement of flexible PUF. Furthermore, cone calorimeter testing revealed the superior fire safety performance of the coated foam, including very low heat and smoke release upon burning. The flame retardancy of the coated PUFs is tunable depending on the amount of graphite employed in the coating solutions. It is anticipated that the coating strategy described here is applicable to other substrates.