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Phosphaphenanthrene-modified zirconium phosphate nanosheets for improving fire resistance, smoke suppression and water tolerance of intumescent coatings

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Abstract

Developing intumescent fire-retardant coatings (IFRCs) combining superior smoke suppression and water resistance is crucial for their industrial applications. Herein, novel 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO)-decorated zirconium phosphate (ZrP-D) nanosheets are synthesized and employed in the IFRCs. The ZrP-D nanosheets feature multifunctionality, which simultaneously improve the fire resistance, smoke suppression, thermal stability and water tolerance of IFRCs. Notably, introducing 3wt% ZrP-D decreases the backside temperature of IFRC from 293.9 to 166.3°C by ~ 43.4% in fire resistance test, followed by 47.9%, 33.5% and 89.4% reductions in peak heat release rate, total heat release and total smoke release. Moreover, this IFRC exhibits improved thermal stability and water tolerance, of which char yield and water contact angle reach up to 64% and 82.7°, respectively. When exposed to high-temperature flame, the ZrP-D nanoplatelets mainly function in condensed phase, which significantly increases the expansion and compactness of residual char due to the barrier and catalytic charring effects, thus suppressing the heat release and smoke diffusion. This work provides a rational design for creating intumescent fire-retardant coatings combining smoke suppression and water resistance, thus possessing broad prospects in industry.

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Acknowledgments

This work is supported by the National Natural Science Foundation of China (NSFC51903193, NSFC51973169), the Foundation for Outstanding Youth Innovative Research Groups of Higher Education Institution in Hubei Province (T201706), the Foundation for Innovative Research Groups of Hubei Natural Science Foundation of China (2017CFA009), and the China Postdoctoral Science Foundation (No. 2022T150557).

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Authors and Affiliations

  1. Hubei Engineering Technology Research Center of Optoelectronic and New Energy Materials, School of Materials Science and Engineering, Wuhan Institute of Technology, Wuhan, 430205, People’s Republic of China

    Cheng Wang, Guofeng Ye & Zhitian Liu

  2. Laboratory of Polymer Materials and Engineering, NingboTech University, No.1 Qianhu South Road, Ningbo, 315100, China

    Siqi Huo & Zhengping Fang

  3. MOE Key Laboratory of Macromolecular Synthesis and Functionalization, Department of Polymer Science and Engineering, Zhejiang University, Hangzhou, 310027, China

    Siqi Huo & Zhengping Fang

  4. Center for Future Materials, University of Southern Queensland, Toowoomba, 4350, Australia

    Hao Wang

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  1. Cheng Wang
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Contributions

CW: Data curation, Formal analysis, Writing—original draft. SH: Formal analysis, Writing—review & editing, Funding acquisition. GY: Data curation. QS: Data curation. ZF: Supervision. HW: Supervision. ZL: Supervision.

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Correspondence to Siqi Huo or Zhitian Liu.

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Wang, C., Huo, S., Ye, G. et al. Phosphaphenanthrene-modified zirconium phosphate nanosheets for improving fire resistance, smoke suppression and water tolerance of intumescent coatings. J Coat Technol Res 20, 1353–1367 (2023). https://doi.org/10.1007/s11998-022-00749-0

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