To enhance the flame retardancy and smoke suppression of silicone rubber foam (SRF), a composite material of hydroxylated carbon nanotubes (CNTs–OH)/ Mg(OH)2/ SRF was synthesized. The flame retardancy, smoke suppression performance of the SRF composites were evaluated using limiting oxygen index (LOI), horizontal-vertical burning tests (UL-94), cone calorimetry, and smoke density testing. Furthermore, the composition and toxicity of the combustion-generated smoke were investigated through a smoke density chamber coupled with Fourier-transform infrared spectroscopy and animal toxicity experiments. The results indicate that the SRF composites with 1.5 wt% CNTs–OH and 7 wt% Mg(OH)2 displayed optimal flame retardancy and smoke suppression, as evidenced by an LOI value of 30.5 % and a UL-94 V-0 classification. The peak heat release rate and total heat release are diminished by 35.5 % and 51.9 %, while the maximum smoke density and total smoke production are lowered by 69.6 % and 70.45 %, respectively. SO2 was identified as the most critical gas causing casualties during the combustion of SRF composites, followed by CO2 and CO. The SRF composite with 1.5 wt% CNTs–OH and 7 wt% Mg(OH)2 was assigned a toxicity rating of ZA1. Moreover, studies reveal that the Mg(OH)2/CNTs–OH/SRF composite achieves flame retardancy via condensed-phase mechanisms, including Mg(OH)2-catalyzed dehydration of CNTs–OH to form a dense char, char stabilization by MgO, and the dilution of combustibles by H2O. Synergistic effects establish dual SiO2/carbon barriers that block heat and oxygen transfer, enhancing fire resistance and smoke suppression.
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