Grantee Research Project Results

A process for making non-halogenated, non-toxic flame retardant polymeric composites has been successfully developed by reacting a polymerizable monomer with an optional crosslinker in the presence of solid nanoparticles, and polymerization initiators to form pre-coat particles. Flame retardant composites were then prepared by using the pre-coat particles together with phosphorus containing compounds to produce non-halogenated, non-toxic flame retarding polymeric composites which could be used as insulation materials.  

 

A non-toxic, low-cost nanocomposite flame retardant can find its use in current building materials, including flexible and rigid polyurethane foam, high-impact polystyrene and expandable polystyrene. The innovation of this method is to use a non­toxic, nanoparticles and superabsorbent polymers to form a heat insulation layer and flame retarding layer that will inhibit and stop the polymer combustion process. The primary focus of this Phase I project is to synthesize the composite structure and to demonstrate the flame retarding capability by achieving equivalent performance to current halogenated flame retardants in terms of bum test ratings. The compatibility of this flame retardant with building materials has been demonstrated by synthesizing plastic foam articles loaded with the proposed composite flame retardant.

 

The experimental results show that the polyurethane based polymeric composites can be prepared as insulation foams which exhibit excellent flame retarding properties and obtain v1 or v0 rating under UL94 vertical flammability test.

The method developed by the present research has proved to be a novel approach to produce non-halogenated, non-toxic polymer composites. The polymer composites exhibit excellent flame retarding properties when superabsorbent polymer coated nano-particles and phosphorous additives were present. The polymer composites so prepared could be used in a wide variety of insulation applications. They include residential (insulation for walls and ceilings), commercial (insulation for office buildings and other non-residential structures), mechanical (insulation of ductwork, pipes, storage tanks, and so on) or for moving objects (cars, trains and aircraft interiors).  

 

Commercialization:

The advantages of this technology include flame retardant characteristics at least equal to current products but lower toxicity and reduced pollution (such as halogen containing acidic gases), and lower human health risk. This material can be produced easily and economically without specialized manufacturing processes, and will be sold at a price comparable to the low end cost of current insulation products.

 

We will promote the flame retarding composite for all facets of the insulation market, including residential, commercial, industrial, mechanical, and specialty niches. This technology is also suitable for multiple forms of insulation, including flexible, rigid, and spray foam, the market for which has been estimated to be a multi-billion dollar global market. Governmental regulations and code call for flame retardant insulation in major market segments such as residential and commercial construction, creating a ready potential need for this material. 

 

Since consumers are increasingly concerned with the health risks associated with flame retardant insulation, the lower toxicity, similar flame retarding perforce and comparable cost shall meet the market need for such a product.