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Novel clay-based coating may point the way to new generation of green flame retardants
Date:6/28/2012

In searching for better flame retardants for home furnishingsa large source of fuel in house firesNational Institute of Standards and Technology (NIST) researchers defied the conventional wisdom and literally hit a wall, one made of clay.

It wasn't a dead end, but rather a surprising result that may lead to a new generation of nonhalogenated, sustainable flame retardant technology for polyurethane foam. The thick, fast-forming coating that the NIST team created has a uniformly high concentration of flame-inhibiting clay particles, and it adheres strongly to the Swiss cheese-like surface of polyurethane foam, which is used in furniture cushions, carpet padding, children's car seats, and other items.

"In effect, we can build the equivalent of a flame-retarding clay wall on the foam in a way that has no adverse impact on the foam manufacturing process," explains NIST fire researcher Rick Davis. "Our clay-based coatings perform at least as well as commercial retardant approaches, and we think there's room for improvement. We hope this new approach provides industry with practical alternative flame retardants."

Davis and his NIST colleagues describe the new coating and the process they used to make it in the journal ACS Macro Letters.*

To date, researchers have built up coatings by stacking thin layers in pairs that are held together by basic electrical attraction. With no clay present, just a pure polymer, a thick coating is formed rapidly, but it isn't a fire retardant. With clay in every other layer, either the coating is too thin or the clay content is too low to be an effective fire retardant.

The NIST team tried something you would expect not to work: trilayers consisting of a positively charged bottom topped by two negatively charged layers. Under most circumstances, the two negative layers would repulse each other, but it turns out that hydrogen bonds formed between the two negative layers and overcame
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Contact: Mark Bello
mark.bello@nist.gov
301-975-3776
National Institute of Standards and Technology (NIST)
Source:Eurekalert  

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