A green flame retardant coating based on one-step aqueous complexation of phytic acid and urea for fabrication of lightweight and high toughness flame retardant EPS insulation board

Green flame retardants have drawn much attention because of their environmental friendliness. But for the high flame retardancy of flammable polymers, most existing green flame retardants are unsatisfactory, even the flameretardant process can not achieve high efficiency and environmental protection. In this work, flame retardants and flame-retardant process are addressed in a two-pronged approach. An eco-friendly bio-based synergistic flame retardant (PAU) was synthesized based on phytic acid (PA) and urea (U) through simple complexation assembly in water. The designed flame retardant coating can be directly coated on the surface of any topological shape with polydopamine as an adhesive. Flame retardant expandable polystyrene (EPS-PAU) with light weight and high toughness is prepared with the designed PAU flame-retardant coating. The coated EPS plates exhibit V0 UL-94 rating and 42.0 % of limited oxygen index and excellent smoke suppression. Moreover, the density of EPS-PAU is slightly increased only by 2.27 % on the basis of the neat EPS, and the hard shell formed using PDA as an adhesive layer is beneficial for the improvement of impact strength. This novel biomass-based PAU system provides a promising strategy for manufacturing polymer products with excellent flame retardancy, smoke inhibition and light weight.

Automated summary

Green flame retardants have garnered attention for their environmental friendliness, but current options fall short in achieving high flame retardancy for flammable polymers and maintaining environmental protection. This study takes a two-pronged approach to address flame retardants and the flame-retardant process. An eco-friendly bio-based synergistic flame retardant (PAU), synthesized using phytic acid (PA) and urea (U), is used to create a flame retardant coating that can be directly applied to any surface shape using polydopamine as an adhesive. The resulting EPS-PAU exhibits excellent flame retardancy, smoke suppression, and light weight while only slightly increasing the density.