Abstract
New types of flame-retardant coatings for rigid polyurethane foam (RPUF) are developed using mixtures of amorphous sodium polyborate (SPB) and various polysaccharides. Based on our previous research reporting that the RPUF coated with a mixture of SPB and starch shows high flame retardancy, polysaccharides such as carboxymethyl cellulose, hydroxyethyl cellulose, glucomannan, 2-hydroxypropyl guar gum (HPG), and gellan gum are used instead of starch. By coating each mixture on the surface, the RPUF (10 mm thickness) endures the premixed flame of butane gas burner with length of 100 mm for more than 12 min, and the backside temperatures remain within the range of 100–160°C. The high flame retardancy is successfully achieved with lower adhesive amounts of the mixtures (8.9–19.1 mg/cm2) than that of the starch/SPB mixture (51.3 mg/cm2). Water resistance is also substantially improved by using gellan gum, CMC, or glucomannan with NaOH. The elution ratio when immersed in water for 12 h is significantly suppressed to 4.8% using the gellan gum/SPB mixture compared with 80.1% using the starch/SPB mixture. The differential thermal analysis and thermogravimetry of the coating mixtures and the scanning electron microscope observations of combustion residues suggest the flame-retardant mechanism that a carbonaceous foam layer is produced from polysaccharides by the action of SPB foam layer and both of the foam layers protect inside from heat and oxygen.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11998-020-00390-9/MediaObjects/11998_2020_390_Fig1_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11998-020-00390-9/MediaObjects/11998_2020_390_Fig2_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11998-020-00390-9/MediaObjects/11998_2020_390_Fig3_HTML.png)
Similar content being viewed by others
Availability of data and materials
The datasets and materials obtained during the current study are available from the corresponding author on reasonable request.
References
van der Veen, I, de Boer, J, “Phosphorus Flame Retardants: Properties, Production, Environmental Occurrence, Toxicity and Analysis.” Chemosphere, 88 (10) 1119–1153 (2012)
Hoffman, K, Gearhart-Serna, L, Lorber, M, Webster, TF, Stapleton, HM, “Estimated Tris(1,3-Dichloro-2-Propyl) Phosphate Exposure Levels for U.S. Infants Suggest Potential Health Risks.” Environ. Sci. Technol. Lett., 4 (8) 334–338 (2017)
Kim, UJ, Kannan, K, “Occurrence and Distribution of Organophosphate Flame Retardants/Plasticizers in Surface Waters, Tap Water, and Rainwater: Implications for Human Exposure.” Environ. Sci. Technol., 52 (10) 5625–5633 (2018)
Gu, JW, Dang, J, Wu, YL, **e, C, Han, Y, “Flame-Retardant, Thermal, Mechanical and Dielectric Properties of Structural Non-halogenated Epoxy Resin Composites.” Polym. Plast. Technol. Eng., 51 (12) 1198–1203 (2012)
Gu, JW, Liang, CB, Zhao, XM, Gan, B, Qiu, H, Guo, YQ, Yang, XT, Zhang, QY, Wang, DY, “Highly Thermally Conductive Flame-Retardant Epoxy Nanocomposites with Reduced Ignitability and Excellent Electrical Conductivities.” Compos. Sci. Technol., 139 83–89 (2017)
Liang, CB, Qiu, H, Song, P, Shi, XT, Kong, J, Gu, JW, “Ultra-Light MXene Aerogel/Wood-Derived Porous Carbon Composites with Wall-Like “Mortar/Brick” Structures for Electromagnetic Interference Shielding.” Sci. Bull., 65 (8) 616–622 (2020)
Lorenzetti, A, Modesti, M, Besco, S, Hrelja, D, Donadi, S, “Influence of Phosphorus Valency on Thermal Behaviour of Flame Retarded Polyurethane Foams.” Polym. Degrad. Stab., 96 (8) 1455–1461 (2011)
Chen, MJ, Xu, YJ, Rao, WH, Huang, JQ, Wang, XL, Chen, L, Wang, YZ, “Influence of Valence and Structure of Phosphorus-Containing Melamine Salts on the Decomposition and Fire Behaviors of Flexible Polyurethane Foams.” Ind. Eng. Chem. Res., 53 (21) 8773–8783 (2014)
Cao, ZJ, Dong, X, Fu, T, Deng, SB, Liao, W, Wang, YZ, “Coated vs. Naked Red Phosphorus: A Comparative Study on Their Fire Retardancy and Smoke Suppression for Rigid Polyurethane Foams.” Polym. Degrad. Stab., 136 103–111 (2017)
Modesti, M, Lorenzetti, A, Simioni, F, Camino, G, “Expandable Graphite as an Intumescent Flame Retardant in Polyisocyanurate-Polyurethane Foams.” Polym. Degrad. Stab., 77 (2) 195–202 (2002)
Shi, L, Li, ZM, **e, BH, Wang, JH, Tian, CR, Yang, MB, “Flame Retardancy of Different-Sized Expandable Graphite Particles for High-Density Rigid Polyurethane Foams.” Polym. Int., 55 (8) 862–871 (2006)
Thirumal, M, Khastgir, D, Singha, NK, Manjunath, BS, Naik, YP, “Effect of Expandable Graphite on the Properties of Intumescent Flame-Retardant Polyurethane Foam.” J. Appl. Polym. Sci., 110 (5) 2586–2594 (2008)
Modesti, M, Lorenzetti, A, Besco, S, Hrelja, D, Semenzato, S, Bertani, R, Michelin, RA, “Synergism Between Flame Retardant and Modified Layered Silicate on Thermal Stability and Fire Behaviour of Polyurethane Nanocomposite Foams.” Polym. Degrad. Stab., 93 (12) 2166–2171 (2008)
Zheng, X, Wang, G, Xu, W, “Roles of Organically-Modified Montmorillonite and Phosphorous Flame Retardant During the Combustion of Rigid Polyurethane Foam.” Polym. Degrad. Stab., 101 32–39 (2014)
Liu, Y, He, J, Yang, R, “The Synthesis of Melamine-Based Polyether Polyol and Its Effects on the Flame Retardancy and Physical–Mechanical Property of Rigid Polyurethane Foam.” J. Mater. Sci., 52 (8) 4700–4712 (2017)
Tsuyumoto, I, Oshio, T, Katayama, K, “Preparation of Highly Concentrated Aqueous Solution of Sodium Borate.” Inorg. Chem. Commun., 10 (1) 20–22 (2007)
Tsuyumoto, I, “A Novel Sodium Silicate Fluoride Solution and a H2 Gas Formed by a Reaction Between Si and an Aqueous Solution of NaOH and NaF.” J. Am. Ceram. Soc., 88 (6) 1628–1630 (2005)
Tsuyumoto, I, Oshio, T, “Development of Fire Resistant Laminated Wood Using Concentrated Sodium Polyborate Aqueous Solution.” J. Wood Chem. Tech., 29 277–285 (2009)
Tsuyumoto, I, Onoda, Y, Hashizume, F, Kinpara, E, “Flame Retardant Rigid Polyurethane Foams Prepared with Amorphous Sodium Polyborate.” J. Appl. Polym. Sci., 122 (3) 1707–1711 (2011)
Tsuyumoto, I, Miura, Y, Hori, Y, “Fire Resistant Nonwovens of EVOH and PET Treated with Amorphous Sodium Polyborate.” J. Mater. Sci., 45 (9) 2504–2509 (2010)
Tsuyumoto, I, Miura, Y, Nirei, M, Ikurumi, S, Kumagai, T, “Highly Flame Retardant Coating Consisting of Starch and Amorphous Sodium Polyborate.” J. Mater. Sci., 46 (16) 5371–5377 (2011)
Acknowledgements
The author is deeply grateful to T. Koike, A. Shimazaki, T. Miyata, H. Kokai, and F. Miyake for their assistance in the experiments. This work was partially supported by a Grant-in-Aid for Scientific Research (C), KAKENHI, No. 16K05946, from the Japan Society for the Promotion of Science (JSPS).
Funding
The research was partially supported by a Grant-in-Aid for Scientific Research (C), KAKENHI, No. 16K05946, from the Japan Society for the Promotion of Science (JSPS).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The author declares no conflict of interest related to this work.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Tsuyumoto, I. Flame-retardant coatings for rigid polyurethane foam based on mixtures of polysaccharides and polyborate. J Coat Technol Res 18, 155–162 (2021). https://doi.org/10.1007/s11998-020-00390-9
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11998-020-00390-9