Biomimetic aerogel coatings for flexible polyurethane foams with superior flame retardancy, mechanical flexibility and antibacterial properties

Abstract

Flexible polyurethane foams (FPUFs) are widely used in various industries due to its high rebound characteristics, but its inherent flammability significantly affects its application. In this study, inspired by the structure of shell nacre, an aerogel coating with gelatin, boric acid and tetrakis hydroxymethyl phosphonium sulfate (THPS) as raw materials was designed. Owing to the hydrogen bonding interactions among the above molecules, the aerogel coating exhibits strong interfacial adhesion to the FPUF substrate, and the peel strength even surpasses the intrinsic strength of the FPUF matrix. Moreover, the coated FPUFs exhibit exceptional flame retardant and thermal insulation properties. The LOI value reaches as high as over 80 % and easily achieves a UL-94 V0 rating. During combustion, the coated FPUFs illustrate extremely low heat and smoke release. Meanwhile, the coated FPUFs still maintain excellent resilience. In addition, the THPS endows coated FPUFs with excellent antibacterial properties and exhibits a highly inhibition against Escherichia coli and Staphylococcus aureus.