Fabrication of green montmorillonite modified bio-based rigid polyurethane foam with improved flame retardancy and enhanced mechanical properties

A low-carbon and sustainable green rigid polyurethane foam was prepared by compounding montmorillonite (MMT) with homemade barium phytate (BAPA). The flame retardancy, thermal stability and mechanical properties of the modified RPUFs investigated using the limiting oxygen index (LOI) method, cone calorimetry (CONE) and thermogravimetry. The results showed that the BAPA/MMT2 composite containing 2 wt% MMT had the highest LOI (25.1 %), and its peak heat release rate (PHRR) and total heat release (THR) were reduced by 14.33 % and 34.68 %, respectively, compared with that of the BAPA/MMT0 material without added MMT. In addition, the smoke production rate (SPR) and total smoke release (TSR) were reduced by 20.54 % and 30.77 %, respectively. BAPA/MMT2 had good flame retardancy and smoke suppression effect. The mechanical properties of BAPA/MMT2 with 2 wt% MMT were improved. The flame retardant mechanism confirmed that BAPA and MMT synergistically improved the quality of the carbon layer. At the same time, phosphorus-containing compounds (PO·), CO₂ and water vapor were produced, which diluted the combustible gas in the gas phase and inhibit the flames spread. The current results provided a new strategy for the preparation of high-performance RPUFs.