An efficient, environmentally friendly,
and water-applied flame
retardant surface nanocoating based on polydopamine (PDA) was developed
for foamed materials such as polyurethane (PU). The PDA nanocoating,
deposited by simple dip-coating in an aqueous dopamine solution, consists
of a planar sublayer and a secondary granular layer structure that
evolve together, eventually turning into a dense, uniform, and conformal
layer on all foam surfaces. In contrast to flexible PU foams that
are known to be highly flammable without flame retardant additives,
micro combustion calorimetry (MCC) and thermogravimetric analysis
(TGA) confirm that the neat PDA is relatively inflammable with a strong
tendency to form carbonaceous, porous char that is highly advantageous
for flame retardancy. By depositing nanocoatings of PDA onto flexible
PU foams, the flammability of the PU foam was significantly reduced
with increasing coating thickness. For the thickest coating (3 days
of PDA deposition), the foam quickly self-extinguished and its original
shape was completely preserved after exposure to a flame in a torch
burn test. In addition to the char forming ability of PDA, it is hypothesized
that its catechol units likely scavenge nearby radicals that typically
evolve additional fuel for the fire as they attack surrounding materials.
This multiple flame retardancy action of PDA (i.e., char formation
+ radical scavenging) enables flame retardant foams with a peak heat
release rate (P-HRR) that is significantly reduced (up to 67%) relative
to control foams, representing much better performance than many conventional
additives reported in the literature at comparable or higher loadings.
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