In this study, a kind of inorganic composite flame retardant (Sep@Fe2O3) was prepared by combining solution deposition and calcination methods using sepiolite microfiber material as carrier. This inorganic compound flame retardant was combined with waterborne polyurethane (WPU) through layer-by-layer method to prepare WPU composites. The SEM and EDS, TEM, and XRD were used to characterize the microscopic morphology and crystal structure of WPU composites. Thermogravimetric analysis tests confirmed the good thermal stability of WPU/Sep@Fe2O3 composites; at the temperature of 600°C, the carbon residual percentage of WPU/Sep, WPU/Fe2O3, and WPU/Sep@Fe2O3 composites is 7.3%, 12.2%, and 13.4%, respectively, higher than that of WPU (1.4%). Vertical combustion tests proved better flame-retardant property of WPU/Sep@Fe2O3 composite-coated cotton than noncoated cotton. The microcalorimeter test proved that the PHRR of WPU/Sep@Fe2O3 composites decreased by 61% compared with that of WPU. In addition, after combining with Sep@Fe2O3, the breaking strength of WPU increased by 35%.

A kind of organic/inorganic composite material composed of waterborne polyurethane and sepiolite was prepared in this work. Sepiolite was organically modified by three kinds of silane coupling agents, and then compounded with waterborne polyurethane through layer-by-layer method in order to prepare composite materials. X-ray diffraction (XRD) and Fourier transform infrared (FTIR) show the crystal and chemistry structure of sepiolite samples, and confirmed the preparation of organic sepiolite. Scanning electron microscope (SEM) and energy dispersive X-ray spectroscopy (EDS) showed the surface microstructure and elemental content of sepiolite and organic sepiolite, and was consistent with the XRD results. Transmission electron microscope (TEM) examination of waterborne polyurethane composites surfaces showed that sepiolite particles were regularly dispersed in the waterborne polyurethane matrix. Thermal resistance of waterborne polyurethane composites was determined by thermogravimetry analyzer (TG) and derivative thermogravimetry analyzer (DTG), differential scanning calorimetry (DSC), gas chromatography (GC), and mass chromatography (MS). Mechanical behavior was examined by tensile strength tester, showed higher break strength than that of the control waterborne polyurethane. Therefore, organically modified sepiolite was considered to be a kind of wonderful inorganic material that could be used to improve the thermal stability and mechanical property of polymer.

Sepiolite-based composites have great potential for application as flame-retardant and thermal-insulation material but their application and development are limited by poor mechanical properties. The objective of the present study was to combine polyvinyl alcohol (PVA) and 3-aminopropyltriethoxysilane (KH-550) with sepiolite (Sep) to improve its aerogel strength. A universal testing machine, thermogravimetry, and microcalorimetry were used to investigate the mechanical properties, thermal-stability, and flame-retardant properties, respectively, of aerogels. The results indicated that KH-550 can enhance effectively the mechanical properties and flame retardancy of aerogels. The compressive modulus of PVA/Sep vs KH-550/PVA/Sep aerogel was 209.28 vs. 474.43 kPa, the LOI index changed from 26.4 to 30.4%. The porosity of the aerogels was > 96% and the density was < 0.05 g/cm3. The thermal conductivity remained at between 0.0340 and 0.0390 W/(m·K), and the aerogel could recover to > 85% after a 50% compressive deformation. These data indicated that Sep-based aerogel would act as a flame retardant and a thermal insulating material with excellent mechanical properties.

To impart durable flame retardant property to cotton fabric, a kind of multilayered hybrid film based on environmentally friendly phytic acid, sepiolite, polyaspartic acid, and Fe3+ were deposited on the surface of cotton fabric by layer-by-layer and spraying method to form a dense protective layer. Compared with cotton fabric, hybrid film coated cotton showed excellent flame retardant property and low fire hazard, which can be demonstrated by vertical flame test, limiting oxygen index (LOI) and cone calorimeter test. After-flame time and after-glow time of hybrid film coated cotton is 1 s and 1 s, respectively. LOI value of hybrid film coated cotton increased by 44.4% compared with control sample. Cone calorimeter test revealed a total heat release rate reduction of 52.6% and peak heat release rate reduction of 73.6% for hybrid film coated cotton fabric. This work demonstrates that the hybrid film composed of phytic acid, sepiolite, polyaspartic acid, and Fe3+ could improve the durable flame retardant property of cotton fabric.