Enhancing flame retardancy, anti-impact, and corrosive resistance of TPU nanocomposites using surface decoration of α-ZrP

The development of polyurethane composites with significant flame retardancy and corrosion resistance for widening its practical application is a great importance. In this study, supramolecular wrapped α-ZrP (MCP@ZrP) was prepared via self-assembly of melamine, cobalt ions (Co 2+ ) and phytic acid (PA) on the surfaces of α-zirconium phosphate (α-ZrP). It was found that both compatibility and dispersion of α-ZrP sheets in thermoplastic polyurethane (TPU) matrices were improved with the incorporation of organic supramolecular components in TPU/MCP@ZrP nanocomposites. Moreover, their fire-retardant characteristic was significantly enhanced, along with effective suppression of smoke and toxic gas emission. By adding 5 wt% MCP@ZrP, peak heat release rate, total heat release, total smoke production, and total CO production of such nanocomposites were reduced by 35.66%, 18.01%, 15.52%, and 41.42%, respectively. The generation of a continuous and dense char layer benefited from well-dispersed MCP@ZrP nanohybrids, which resulted in tortuous effect to impede heat diffusion and prevent the evaporation of volatile gasses. By means of the barrier effect of ZrP, TPU/MCP@ZrP composite films also showed improved anticorrosion performance. Effective interfacial adhesion, achieved by combining MCP supermolecules and α-ZrP sheets, offers a viable approach to improve protective properties of TPU nanocomposites. Highlights Supramolecular-wrapped α-ZrP was prepared via self-assembly strategy. MCP@ZrP showed good dispersion and interface adhesion within TPU matrices. MCP@ZrP enhanced the flame retardancy and mechanical performance of TPU. MCP@ZrP preventing smoke and toxic gas evaporation.