Improving the fire-resistant efficiency of silicone-based
polymeric
coatings is important in the building industry and electrical utilities.
In this study, the water-containing hybrid calcium carbonate (CaCO3)–silica (SiO2) colloidal capsule has been
developed and optimized as an inorganic flame-retardant additive.
This capsule exhibits excellent thermal stability up to 1000 °C
with a remaining intact hollow spherical structure. When used as an
inorganic filler at 15 wt %, it not only reduces the potential fire
hazards by over 44% (i.e., the sumHRC reduced from 112.00 J/g K to
62.00 J/g K) but also improves the heat-barrier efficiency by over
30% (i.e., the temperature at the steady state reduced from 350 to
360 °C to below 250 °C) of the silicone-based polymeric
coatings. In addition, the capsule–polymer composite coating
exhibits excellent ductility which can withstand heat-induced mechanical
stresses and prevent crack propagation under radiative heating conditions.
The fire-resistant mechanism of the colloidal capsule is related strongly
to the encapsulated water core and the reactions between SiO2 and CaCO3 at elevated temperatures. They not only contribute
to a cooling effect on the flammable pyrolysis gases but also induce
the insulative effect to the resulted char during combustion. The
significant advances in this study will have a high impact in customizing
the functional inorganic additives for a better design of the flame-retardant
composite coating.