Synthesis and comprehensive study on industrially relevant flame retardant waterborne polyurethanes based on phosphorus chemistry

A series of novel industrially relevant halogen-free flame retardant self-curable silanized waterborne polyurethane (WPU) coatings were successfully synthesized. The effect of reactive-type phosphorus flame retardant diol (Exolit® OP560) incorporation into PU structure was investigated. High limit oxygen index (LOI) value of 30.4% accompanied by V0 classification of UL-94 vertical burning test confirmed promising flame retardancy of the WPU film containing 8.7 wt% OP560. Furthermore, microscale combustion calorimeter (MCC) indicated the obvious decrease in the heat release rate (HRR), the temperature of maximum HRR, total HR, and HR capacity (HRC) of WPUs by adding phosphorus diol. TGA, SEM, MCC, and TG-IR studies revealed that great improvement in flame retardancy was due to not only integral char formation through the synergistic effect of phosphorus and silicon but also gas dilution effect. Moreover, bio-based polyol (castor oil) was added to the formulation to increase water contact angle and water resistance. High flame retardancy and enhanced mechanical properties make this formulation highly relevant for industrial applications.