Water-based hybrid coatings toward mechanically flexible, super-hydrophobic and flame-retardant polyurethane foam nanocomposites with high-efficiency and reliable fire alarm response

Flammability feature of combustible polymer foam materials often causes massive casualties and property loss, and it is therefore urgent to develop a green and high-efficiency strategy that can reduce or avoid the fire blaze disasters. Here, an extremely simple water-based coating approach is proposed to prepare mechanically flexible, super-hydrophobic and flame-retardant polyurethane (PU) foam nanocomposites with high-efficiency fire warning response. The hybrid ammonium polyphosphate (APP)/graphene oxide (GO) is decorated onto the PU foam surface via electrostatic interactions followed by surface silane functionalization. Interestingly, the silane and APP molecules present selective distributions on the GO and thus form micro-/nano- rough surface with low water affinity to achieve super-hydrophobicity (e.g. water contact angle of ~158.4°). Meanwhile, such hybrid APP/GO/silane coatings produce synergistic flame resistance for the PU foam materials, which is attributed to the formation of compact and uniform P-Si elements co-covered rGO layer on the foam surface. Further, the hybrid coatings can provide high-efficiency fire warning response under complicated conditions, e.g. flame detection response time of only ~2.0 s and excellent fire early warning time in pre-combustion (e.g. 11.2 s at 300 °C). Therefore, this work provides new perspectives to design and develop multi-functional coatings for fire safety and prevention applications.