Utilization of hybrid silicone rubber/Exolit AP 422 composite for the fabrication of mechanically flexible, flame-retardant and superhydrophobic polyurethane foams

Flammability of burnable polymer foams usually results in irrecoverable property loss and massive casualties. Thus, it is vital to build up a green and highly efficient method to minimize or prevent the fire-generated disasters. Herein, we developed a facile single-step production of superhydrophobic and flame-retardant polyurethane foam (PUF) via coating with a hybrid of room temperature vulcanized silicone rubber (SR) and Exolit (Ex) AP 422 (Ex is ammonium polyphosphate). The flame-resistant effect of PUF was improved owing to the high binding of SR-Ex hybrid and PUF. Results revealed that the treated PUF samples have a nano-scaled hierarchically rough surface morphologies, depending on the total content of the added Exolit AP 422. Given that SR was employed to enhance the superhydrphobic activity on the surface of the treated PUF, the superhydrophobic performance was probed via static water contact angle of SR-Ex/PUF which displayed angles the range of 138.1-152.6 degrees. The comfort properties of the SR-Ex/PUF samples were evaluated by exploring their stiffness and air permeability. The CIE Lab colorimetric properties and UV-Vis absorption spectra of the prepared SR-Ex/PUF samples were explored to demonstrate no adverse effects on the physico-mechanical properties of the treated samples.